Surgical instrument with wireless communication between control unit and sensor transponders

ABSTRACT

A surgical instrument is disclosed. The surgical instrument includes a control unit and a staple cartridge including a transponder. The control unit is configured to transmit a first wireless signal to the transponder and to receive a second wireless signal from the transponder to determine one of a first electronic state and a second electronic state of the transponder based on the second wireless signal.

CROSS REFERENCE TO RELATED APPLICATION

The present application is a continuation of U.S. patent application Ser. No. 11/651,715, filed, Jan. 10, 2007, and is related to the following U.S. patent applications, which are incorporated herein by reference:

(1) U.S. patent application Ser. No. 11/651,807 entitled “SURGICAL INSTRUMENT WITH WIRELESS COMMUNICATION BETWEEN CONTROL UNIT AND REMOTE SENSOR,” by J. Giordano et al., now U.S. Patent Publication 2008-0167672 A1;

(2) U.S. patent application Ser. No. 11/651,806 entitled “SURGICAL INSTRUMENT WITH ELEMENTS TO COMMUNICATE BETWEEN CONTROL UNIT AND END EFFECTOR,” by J. Giordano et al., now U.S. Patent Publication 2008-0167671 A1;

(3) U.S. patent application Ser. No. 11/651,768 entitled “PREVENTION OF CARTRIDGE REUSE IN A SURGICAL INSTRUMENT,” by F. Shelton et al., now U.S. Pat. No. 7,721,931;

(4) U.S. patent application Ser. No. 11/651,771 entitled “POST-STERILIZATION PROGRAMMING OF SURGICAL INSTRUMENTS,” by J. Swayze et al., now U.S. Patent Publication 2008-0167736 A1;

(5) U.S. patent application Ser. No. 11/651,788 entitled “INTERLOCK AND SURGICAL INSTRUMENT INCLUDING SAME, by F. Shelton et al., now U.S. Pat. No. 7,721,936; and

(6) U.S. patent application Ser. No. 11/651,785 entitled “SURGICAL INSTRUMENT WITH ENHANCED BATTERY PERFORMANCE,” by F. Shelton et al., now U.S. Patent Publication 2008-0167644 A1.

BACKGROUND

Endoscopic surgical instruments are often preferred over traditional open surgical devices since a smaller incision tends to reduce the post-operative recovery time and complications. Consequently, significant development has gone into a range of endoscopic surgical instruments that are suitable for precise placement of a distal end effector at a desired surgical site through a cannula of a trocar. These distal end effectors engage the tissue in a number of ways to achieve a diagnostic or therapeutic effect (e.g., endocutter, grasper, cutter, staplers, clip applier, access device, drug/gene therapy delivery device, and energy device using ultrasound, RF, laser, etc.).

Known surgical staplers include an end effector that simultaneously makes a longitudinal incision in tissue and applies lines of staples on opposing sides of the incision. The end effector includes a pair of cooperating jaw members that, if the instrument is intended for endoscopic or laparoscopic applications, are capable of passing through a cannula passageway. One of the jaw members receives a staple cartridge having at least two laterally spaced rows of staples. The other jaw member defines an anvil having staple-forming pockets aligned with the rows of staples in the cartridge. The instrument includes a plurality of reciprocating wedges which, when driven distally, pass through openings in the staple cartridge and engage drivers supporting the staples to effect the firing of the staples toward the anvil.

Advantageously, the design of the end effector may be such that it can be reused with the surgical stapler. For instance, one patient may need a series of severing and stapling operations. Replacing an entire end effector for each operation tends to be economically inefficient, especially if the end effector is built for strength and reliability over repeated operations. To that end, the staple cartridge is typically configured to be disposable and is fitted into the end effector prior to each operation of the surgical stapler.

An example of a surgical stapler suitable for endoscopic applications is described in U.S. Pat. No. 5,465,895, which discloses an endocutter with distinct closing and firing actions. A clinician using this device is able to close the jaw members upon tissue to position the tissue prior to firing. Once the clinician has determined that the jaw members are properly gripping tissue, the clinician can then fire the surgical stapler with a single firing stroke, thereby severing and stapling the tissue. The simultaneous severing and stapling avoids complications that may arise when performing such actions sequentially with different surgical tools that respectively only sever and staple.

One specific advantage of being able to close upon tissue before firing is that the clinician is able to verify via an endoscope that the desired location for the cut has been achieved, including that a sufficient amount of tissue has been captured between opposing jaws. Otherwise, opposing jaws may be drawn too close together, especially pinching at their distal ends, and thus not effectively forming closed staples in the severed tissue. At the other extreme, an excessive amount of clamped tissue may cause binding and an incomplete firing.

Endoscopic staplers/cutters continue to increase in complexity and function with each generation. One of the main reasons for this is the quest to lower force-to-fire (FTF) to a level that all or a great majority of surgeons can handle. One known solution to lower FTF it use CO₂ or electrical motors. These devices have not faired much better than traditional hand-powered devices, but for a different reason. Surgeons typically prefer to experience proportionate force distribution to that being experienced by the end effector in the forming of the staple to assure them that the cutting/stapling cycle is complete, with the upper limit within the capabilities of most surgeons (usually around 15-30 lbs). They also typically want to maintain control of deploying the staples and being able to stop at anytime if the forces felt in the handle of the device feel too great or for some other clinical reason.

To address this need, so-called “power-assist” endoscopic surgical instruments have been developed in which a supplemental power source aids in the firing of the instrument. For example, in some power-assist devices, a motor provides supplemental electrical power to the power input by the user from squeezing the firing trigger. Such devices are capable of providing loading force feedback and control to the operator to reduce the firing force required to be exerted by the operator in order to complete the cutting operation. One such power-assist device is described in U.S. patent application Ser. No. 11/343,573, filed Jan. 31, 2006 by Shelton et al., entitled “Motor-driven surgical cutting and fastening instrument with loading force feedback,” (“the '573 application”) which is incorporated herein by reference.

These power-assist devices often include other components that purely mechanical endoscopic surgical instruments do not, such as sensors and control systems. One challenge in using such electronics in a surgical instrument is delivering power and/or data to and from the sensors, particularly when there is a free rotating joint in the surgical instrument.

Although powered instruments provide numerous advantages, it is desirable to prevent inadvertent firing of the instrument under certain conditions. For example, firing the instrument without having a staple cartridge installed, or firing the instrument having an installed but spent (e.g., previously fired) staple cartridge, may result in cutting of tissue without simultaneous stapling to minimize bleeding. Electronic controls, or interlocks, for preventing powered endocutter operation under such conditions have heretofore utilized active electrical circuits disposed in the end effector for determining whether an unspent staple cartridge has been installed in the end effector. For example, U.S. Pat. No. 5,529,235 entitled IDENTIFICATION DEVICE FOR SURGICAL STAPLING INSTRUMENT to Boiarski et al. discloses an interlock circuit integral to the staple cartridge and having a fuse that is opened responsive to a mechanical force or electrical current applied thereto concurrent with a firing operation. The open electrical state of the fuse is detected via a hardwired control circuit externally located with respect to the end effector to prevent a subsequent firing operation using a spent staple cartridge. In this way, opening the fuse disables the staple cartridge and prevents is reuse.

U.S. patent application Ser. No. 11/343,439 entitled “ELECTRONIC INTERLOCKS AND SURGICAL INSTRUMENT INCLUDING SAME” to Swayze et al. discloses the use of electronic sensors disposed within the end effector for determining if an unspent staple cartridge has been installed. The sensors may include switches connected in series with a motor or other electrically-powered actuation mechanism such that current flow necessary for generating the actuation force is prevented when the staple cartridge is not installed, or when the staple cartridge is installed but spent.

Although the above-described electronic controls are generally effective for preventing inadvertent instrument operation, placement of electronics in the end effector has heretofore required electrical cabling to connect the end effector with other electrical components (e.g., power sources, motors, control circuits, etc.) externally located with respect to the end effector. In cases where such electrical components are disposed within a handle of the instrument (as in the above-described references), the electrical cabling is typically routed via a shaft connecting the end effector to the handle. However, routing electrical cabling in this manner is inconvenient and increases instrument complexity and cost.

In addition to preventing firing of the instrument in the absence of an unspent staple cartridge, it may further be desirable to limit the number of firing operations that may be performed by the instrument.

Consequently, a significant need exists for electronic controls for use in powered cutting and stapling instruments that prevent inadvertent firing (e.g., cutting but not stapling) while avoiding complexities associated with hardwired end effector electronics, and that limit instrument use to a predetermined number of firing operations.

SUMMARY

In one general aspect, the present application is directed to a surgical instrument, such as an endoscopic or laparoscopic instrument. According to one embodiment, the surgical instrument comprises an end effector comprising at least one sensor transponder that is passively powered. The surgical instrument also comprises a shaft having a distal end connected to the end effector and a handle connected to a proximate end of the shaft. The handle comprises a control unit (e.g., a microcontroller) that is in communication with the sensor transponder via at least one inductive coupling. Further, the surgical instrument may comprise a rotational joint for rotating the shaft. In such a case, the surgical instrument may comprise a first inductive element located in the shaft distally from the rotational joint and inductively coupled to the control unit, and a second inductive element located distally in the shaft and inductively coupled to the at least one sensor transponder. The first and second inductive elements may be connected by a wired, physical connection.

That way, the control unit may communicate with the transponder in the end effector without a direct wired connection through complex mechanical joints like the rotating joint where it may be difficult to maintain such a wired connection. In addition, because the distances between the inductive elements may be fixed and known, the couplings could be optimized for inductive transfer of energy. Also, the distances could be relatively short so that relatively low power signals could be used to thereby minimize interference with other systems in the use environment of the instrument.

In another general aspect of the present application, the electrically conductive shaft of the surgical instrument may serve as an antenna for the control unit to wirelessly communicate signals to and from the sensor transponder. For example, the sensor transponder could be located on or disposed in a nonconductive component of the end effector, such as a plastic cartridge, thereby insulating the sensor from conductive components of the end effector and the shaft. In addition, the control unit in the handle may be electrically coupled to the shaft. In that way, the shaft and/or the end effector may serve as an antenna for the control unit by radiating signals from the control unit to the sensor and/or by receiving radiated signals from the sensor. Such a design is particularly useful in surgical instruments having complex mechanical joints (such as rotary joints), which make it difficult to use a direct wired connection between the sensor and control unit for communicating data signals.

In another embodiment, the shaft and/or components of the end effector could serve as the antenna for the sensor by radiating signals to the control unit and receiving radiated signals from the control unit. According to such an embodiment, the control unit is electrically insulated from the shaft and the end effector.

In another general aspect, the present application is directed to a surgical instrument comprising a programmable control unit that can be programmed by a programming device after the instrument has been packaged and sterilized. In one such embodiment, the programming device may wirelessly program the control unit. The control unit may be passively powered by the wireless signals from the programming device during the programming operation. In another embodiment, the sterile container may comprise a connection interface so that the programming unit can be connected to the surgical instrument while the surgical instrument is in its sterilized container.

In one embodiment, the surgical instrument includes a control unit and a staple cartridge including a transponder. The control unit is configured to transmit a first wireless signal to the transponder and to receive a second wireless signal from the transponder to determine one of a first electronic state and a second electronic state of the transponder based on the second wireless signal.

In another embodiment, the instrument includes an end effector comprising a moveable cutting instrument to cut an object, and a motor coupled to the end effector to actuate the cutting instrument. Each actuation of the cutting instrument corresponding to a firing operation by the surgical instrument. The surgical instrument further includes a control unit to count a number of firing operations by the surgical instrument and to electronically alter at least one component of the instrument when the number of firing operations is equal to a predetermined number. The altered at least one component prevents firing operations by the surgical instrument in excess of the predetermined number.

This application further discloses a staple cartridge for use in a surgical instrument. The staple cartridge includes a transponder transitionable from a first electronic state to a second electronic state. The first electronic state is indicative of an unfired state of the staple cartridge and the second electronic state is indicative of a fired state of the staple cartridge.

FIGURES

Various embodiments of the present application are described herein by way of example in conjunction with the following figures wherein:

FIGS. 1 and 2 are perspective views of a surgical instrument according to various embodiments of the present application;

FIGS. 3-5 are exploded views of an end effector and shaft of the instrument according to various embodiments of the present application;

FIG. 6 is a side view of the end effector according to various embodiments of the present application;

FIG. 7 is an exploded view of the handle of the instrument according to various embodiments of the present application;

FIGS. 8 and 9 are partial perspective views of the handle according to various embodiments of the present application;

FIG. 10 is a side view of the handle according to various embodiments of the present application;

FIGS. 11, 13-14, 16, and 22 are perspective views of a surgical instrument according to various embodiments of the present application;

FIGS. 12 and 19 are block diagrams of a control unit according to various embodiments of the present application;

FIG. 15 is a side view of an end effector including a sensor transponder according to various embodiments of the present application;

FIGS. 17 and 18 show the instrument in a sterile container according to various embodiments of the present application;

FIG. 20 is a block diagram of the remote programming device according to various embodiments of the present application; and

FIG. 21 is a diagram of a packaged instrument according to various embodiments of the present application.

FIGS. 23 and 24 are perspective views of a surgical instrument according to various embodiments of the present application;

FIG. 25A is an exploded view of the end effector according to various embodiments of the present application;

FIG. 25B is a perspective view of the cutting instrument of FIG. 25A;

FIGS. 26 and 27 are exploded views of an end effector and shaft of the instrument according to various embodiments of the present application;

FIG. 28 is a side view of the end effector according to various embodiments of the present application;

FIG. 29 is an exploded view of the handle of the instrument according to various embodiments of the present application;

FIGS. 30 and 31 are partial perspective views of the handle according to various embodiments of the present application;

FIG. 32 is a side view of the handle according to various embodiments of the present application;

FIGS. 33 and 34 illustrate a proportional sensor that may be used according to various embodiments of the present application;

FIG. 35 is a block diagram of a control unit according to various embodiments of the present application;

FIGS. 36-38 and FIG. 48 are perspective views of a surgical instrument according to various embodiments of the present application;

FIG. 39 is a bottom view of a portion of a staple cartridge according to various embodiments;

FIGS. 40 and 42 are circuit diagrams of a transponder according to various embodiments;

FIG. 41 is a bottom view of a portion of a staple cartridge according to various embodiments;

FIG. 43 is a perspective view of a staple cartridge tray according to various embodiments;

FIGS. 44 and 45 are circuit diagrams of a transponder according to various embodiments;

FIG. 46 is a flow diagram of a method of preventing reuse of a staple cartridge in surgical instrument according to various embodiments; and

FIG. 47 is a block diagram of a circuit for preventing operation of the motor according to various embodiments.

DETAILED DESCRIPTION

Various embodiments of the present application are directed generally to a surgical instrument having at least one remote sensor transponder and means for communicating power and/or data signals to the transponder(s) from a control unit. Embodiments of the present application may be used with any type of surgical instrument comprising at least one sensor transponder, such as endoscopic or laparoscopic surgical instruments, but is particularly useful for surgical instruments where some feature of the instrument, such as a free rotating joint, prevents or otherwise inhibits the use of a wired connection to the sensor(s). Before describing aspects of the system, one type of surgical instrument in which embodiments of the present application may be used—an endoscopic stapling and cutting instrument (i.e., an endocutter)—is first described by way of illustration.

FIGS. 1 and 2 depict an endoscopic surgical instrument 10 that comprises a handle 6, a shaft 8, and an articulating end effector 12 pivotally connected to the shaft 8 at an articulation pivot 14. Correct placement and orientation of the end effector 12 may be facilitated by controls on the hand 6, including (1) a rotation knob 28 for rotating the closure tube (described in more detail below in connection with FIGS. 4-5) at a free rotating joint 29 of the shaft 8 to thereby rotate the end effector 12 and (2) an articulation control 16 to effect rotational articulation of the end effector 12 about the articulation pivot 14. In the illustrated embodiment, the end effector 12 is configured to act as an endocutter for clamping, severing and stapling tissue, although in other embodiments, different types of end effectors may be used, such as end effectors for other types of surgical instruments, such as graspers, cutters, staplers, clip appliers, access devices, drug/gene therapy devices, ultrasound, RF or laser devices, etc.

The handle 6 of the instrument 10 may include a closure trigger 18 and a firing trigger 20 for actuating the end effector 12. It will be appreciated that instruments having end effectors directed to different surgical tasks may have different numbers or types of triggers or other suitable controls for operating the end effector 12. The end effector 12 is shown separated from the handle 6 by the preferably elongate shaft 8. In one embodiment, a clinician or operator of the instrument 10 may articulate the end effector 12 relative to the shaft 8 by utilizing the articulation control 16, as described in more detail in pending U.S. patent application Ser. No. 11/329,020, filed Jan. 10, 2006, entitled “Surgical Instrument Having An Articulating End Effector,” by Geoffrey C. Hueil et al., which is incorporated herein by reference.

The end effector 12 includes in this example, among other things, a staple channel 22 and a pivotally translatable clamping member, such as an anvil 24, which are maintained at a spacing that assures effective stapling and severing of tissue clamped in the end effector 12. The handle 6 includes a pistol grip 26 towards which a closure trigger 18 is pivotally drawn by the clinician to cause clamping or closing of the anvil 24 toward the staple channel 22 of the end effector 12 to thereby clamp tissue positioned between the anvil 24 and channel 22. The firing trigger 20 is farther outboard of the closure trigger 18. Once the closure trigger 18 is locked in the closure position, the firing trigger 20 may rotate slightly toward the pistol grip 26 so that it can be reached by the operator using one hand. Then the operator may pivotally draw the firing trigger 20 toward the pistol grip 12 to cause the stapling and severing of clamped tissue in the end effector 12. The '573 application describes various configurations for locking and unlocking the closure trigger 18. In other embodiments, different types of clamping members besides the anvil 24 could be used, such as, for example, an opposing jaw, etc.

It will be appreciated that the terms “proximal” and “distal” are used herein with reference to a clinician gripping the handle 6 of an instrument 10. Thus, the end effector 12 is distal with respect to the more proximal handle 6. It will be further appreciated that, for convenience and clarity, spatial terms such as “vertical” and “horizontal” are used herein with respect to the drawings. However, surgical instruments are used in many orientations and positions, and these terms are not intended to be limiting and absolute.

The closure trigger 18 may be actuated first. Once the clinician is satisfied with the positioning of the end effector 12, the clinician may draw back the closure trigger 18 to its fully closed, locked position proximate to the pistol grip 26. The firing trigger 20 may then be actuated. The firing trigger 20 returns to the open position (shown in FIGS. 1 and 2) when the clinician removes pressure. A release button 30 on the handle 6, and in this example, on the pistol grip 26 of the handle, when depressed may release the locked closure trigger 18.

FIG. 3 is an exploded view of the end effector 12 according to various embodiments. As shown in the illustrated embodiment, the end effector 12 may include, in addition to the previously-mentioned channel 22 and anvil 24, a cutting instrument 32, a sled 33, a staple cartridge 34 that is removably seated in the channel 22, and a helical screw shaft 36. The cutting instrument 32 may be, for example, a knife. The anvil 24 may be pivotably opened and closed at a pivot point 25 connected to the proximate end of the channel 22. The anvil 24 may also include a tab 27 at its proximate end that is inserted into a component of the mechanical closure system (described further below) to open and close the anvil 24. When the closure trigger 18 is actuated, that is, drawn in by a user of the instrument 10, the anvil 24 may pivot about the pivot point 25 into the clamped or closed position. If clamping of the end effector 12 is satisfactory, the operator may actuate the firing trigger 20, which, as explained in more detail below, causes the knife 32 and sled 33 to travel longitudinally along the channel 22, thereby cutting tissue clamped within the end effector 12. The movement of the sled 33 along the channel 22 causes the staples of the staple cartridge 34 to be driven through the severed tissue and against the closed anvil 24, which turns the staples to fasten the severed tissue. U.S. Pat. No. 6,978,921, entitled “Surgical stapling instrument incorporating an E-beam firing mechanism,” which is incorporated herein by reference, provides more details about such two-stroke cutting and fastening instruments. The sled 33 may be part of the cartridge 34, such that when the knife 32 retracts following the cutting operation, the sled 33 does not retract. The channel 22 and the anvil 24 may be made of an electrically conductive material (such as metal) so that they may serve as part of the antenna that communicates with the sensor(s) in the end effector, as described further below. The cartridge 34 could be made of a nonconductive material (such as plastic) and the sensor may be connected to or disposed in the cartridge 34, as described further below.

It should be noted that although the embodiments of the instrument 10 described herein employ an end effector 12 that staples the severed tissue, in other embodiments different techniques for fastening or sealing the severed tissue may be used. For example, end effectors that use RF energy or adhesives to fasten the severed tissue may also be used. U.S. Pat. No. 5,709,680, entitled “Electrosurgical Hemostatic Device” to Yates et al., and U.S. Pat. No. 5,688,270, entitled “Electrosurgical Hemostatic Device With Recessed And/Or Offset Electrodes” to Yates et al., which are incorporated herein by reference, discloses cutting instruments that use RF energy to fasten the severed tissue. U.S. patent application Ser. No. 11/267,811 to Morgan et al. and U.S. patent application Ser. No. 11/267,383 to Shelton et al., which are also incorporated herein by reference, disclose cutting instruments that use adhesives to fasten the severed tissue. Accordingly, although the description herein refers to cutting/stapling operations and the like, it should be recognized that this is an exemplary embodiment and is not meant to be limiting. Other tissue-fastening techniques may also be used.

FIGS. 4 and 5 are exploded views and FIG. 6 is a side view of the end effector 12 and shaft 8 according to various embodiments. As shown in the illustrated embodiment, the shaft 8 may include a proximate closure tube 40 and a distal closure tube 42 pivotably linked by a pivot links 44. The distal closure tube 42 includes an opening 45 into which the tab 27 on the anvil 24 is inserted in order to open and close the anvil 24. Disposed inside the closure tubes 40, 42 may be a proximate spine tube 46. Disposed inside the proximate spine tube 46 may be a main rotational (or proximate) drive shaft 48 that communicates with a secondary (or distal) drive shaft 50 via a bevel gear assembly 52. The secondary drive shaft 50 is connected to a drive gear 54 that engages a proximate drive gear 56 of the helical screw shaft 36. The vertical bevel gear 52 b may sit and pivot in an opening 57 in the distal end of the proximate spine tube 46. A distal spine tube 58 may be used to enclose the secondary drive shaft 50 and the drive gears 54, 56. Collectively, the main drive shaft 48, the secondary drive shaft 50, and the articulation assembly (e.g., the bevel gear assembly 52 a-c), are sometimes referred to herein as the “main drive shaft assembly.” The closure tubes 40, 42 may be made of electrically conductive material (such as metal) so that they may serve as part of the antenna, as described further below. Components of the main drive shaft assembly (e.g., the drive shafts 48, 50) may be made of a nonconductive material (such as plastic).

A bearing 38, positioned at a distal end of the staple channel 22, receives the helical drive screw 36, allowing the helical drive screw 36 to freely rotate with respect to the channel 22. The helical screw shaft 36 may interface a threaded opening (not shown) of the knife 32 such that rotation of the shaft 36 causes the knife 32 to translate distally or proximately (depending on the direction of the rotation) through the staple channel 22. Accordingly, when the main drive shaft 48 is caused to rotate by actuation of the firing trigger 20 (as explained in more detail below), the bevel gear assembly 52 a-c causes the secondary drive shaft 50 to rotate, which in turn, because of the engagement of the drive gears 54, 56, causes the helical screw shaft 36 to rotate, which causes the knife 32 to travel longitudinally along the channel 22 to cut any tissue clamped within the end effector. The sled 33 may be made of, for example, plastic, and may have a sloped distal surface. As the sled 33 traverses the channel 22, the sloped forward surface may push up or drive the staples in the staple cartridge 34 through the clamped tissue and against the anvil 24. The anvil 24 turns the staples, thereby stapling the severed tissue. When the knife 32 is retracted, the knife 32 and sled 33 may become disengaged, thereby leaving the sled 33 at the distal end of the channel 22.

According to various embodiments, as shown FIGS. 7-10, the surgical instrument may include a battery 64 in the handle 6. The illustrated embodiment provides user-feedback regarding the deployment and loading force of the cutting instrument in the end effector 12. In addition, the embodiment may use power provided by the user in retracting the firing trigger 18 to power the instrument 10 (a so-called “power assist” mode). As shown in the illustrated embodiment, the handle 6 includes exterior lower side pieces 59, 60 and exterior upper side pieces 61, 62 that fit together to form, in general, the exterior of the handle 6. The handle pieces 59-62 may be made of an electrically nonconductive material, such as plastic. A battery 64 may be provided in the pistol grip portion 26 of the handle 6. The battery 64 powers a motor 65 disposed in an upper portion of the pistol grip portion 26 of the handle 6. The battery 64 may be constructed according to any suitable construction or chemistry including, for example, a Li-ion chemistry such as LiCoO₂ or LiNiO₂, a Nickel Metal Hydride chemistry, etc. According to various embodiments, the motor 65 may be a DC brushed driving motor having a maximum rotation of, approximately, 5000 RPM to 100,000 RPM. The motor 64 may drive a 90° bevel gear assembly 66 comprising a first bevel gear 68 and a second bevel gear 70. The bevel gear assembly 66 may drive a planetary gear assembly 72. The planetary gear assembly 72 may include a pinion gear 74 connected to a drive shaft 76. The pinion gear 74 may drive a mating ring gear 78 that drives a helical gear drum 80 via a drive shaft 82. A ring 84 may be threaded on the helical gear drum 80. Thus, when the motor 65 rotates, the ring 84 is caused to travel along the helical gear drum 80 by means of the interposed bevel gear assembly 66, planetary gear assembly 72 and ring gear 78.

The handle 6 may also include a run motor sensor 110 in communication with the firing trigger 20 to detect when the firing trigger 20 has been drawn in (or “closed”) toward the pistol grip portion 26 of the handle 6 by the operator to thereby actuate the cutting/stapling operation by the end effector 12. The sensor 110 may be a proportional sensor such as, for example, a rheostat or variable resistor. When the firing trigger 20 is drawn in, the sensor 110 detects the movement, and sends an electrical signal indicative of the voltage (or power) to be supplied to the motor 65. When the sensor 110 is a variable resistor or the like, the rotation of the motor 65 may be generally proportional to the amount of movement of the firing trigger 20. That is, if the operator only draws or closes the firing trigger 20 in a little bit, the rotation of the motor 65 is relatively low. When the firing trigger 20 is fully drawn in (or in the fully closed position), the rotation of the motor 65 is at its maximum. In other words, the harder the user pulls on the firing trigger 20, the more voltage is applied to the motor 65, causing greater rates of rotation. In another embodiment, for example, the control unit (described further below) may output a PWM control signal to the motor 65 based on the input from the sensor 110 in order to control the motor 65.

The handle 6 may include a middle handle piece 104 adjacent to the upper portion of the firing trigger 20. The handle 6 also may comprise a bias spring 112 connected between posts on the middle handle piece 104 and the firing trigger 20. The bias spring 112 may bias the firing trigger 20 to its fully open position. In that way, when the operator releases the firing trigger 20, the bias spring 112 will pull the firing trigger 20 to its open position, thereby removing actuation of the sensor 110, thereby stopping rotation of the motor 65. Moreover, by virtue of the bias spring 112, any time a user closes the firing trigger 20, the user will experience resistance to the closing operation, thereby providing the user with feedback as to the amount of rotation exerted by the motor 65. Further, the operator could stop retracting the firing trigger 20 to thereby remove force from the sensor 100, to thereby stop the motor 65. As such, the user may stop the deployment of the end effector 12, thereby providing a measure of control of the cutting/fastening operation to the operator.

The distal end of the helical gear drum 80 includes a distal drive shaft 120 that drives a ring gear 122, which mates with a pinion gear 124. The pinion gear 124 is connected to the main drive shaft 48 of the main drive shaft assembly. In that way, rotation of the motor 65 causes the main drive shaft assembly to rotate, which causes actuation of the end effector 12, as described above.

The ring 84 threaded on the helical gear drum 80 may include a post 86 that is disposed within a slot 88 of a slotted arm 90. The slotted arm 90 has an opening 92 at its opposite end 94 that receives a pivot pin 96 that is connected between the handle exterior side pieces 59, 60. The pivot pin 96 is also disposed through an opening 100 in the firing trigger 20 and an opening 102 in the middle handle piece 104.

In addition, the handle 6 may include a reverse motor (or end-of-stroke sensor) 130 and a stop motor (or beginning-of-stroke) sensor 142. In various embodiments, the reverse motor sensor 130 may be a limit switch located at the distal end of the helical gear drum 80 such that the ring 84 threaded on the helical gear drum 80 contacts and trips the reverse motor sensor 130 when the ring 84 reaches the distal end of the helical gear drum 80. The reverse motor sensor 130, when activated, sends a signal to the control unit which sends a signal to the motor 65 to reverse its rotation direction, thereby withdrawing the knife 32 of the end effector 12 following the cutting operation.

The stop motor sensor 142 may be, for example, a normally-closed limit switch. In various embodiments, it may be located at the proximate end of the helical gear drum 80 so that the ring 84 trips the switch 142 when the ring 84 reaches the proximate end of the helical gear drum 80.

In operation, when an operator of the instrument 10 pulls back the firing trigger 20, the sensor 110 detects the deployment of the firing trigger 20 and sends a signal to the control unit which sends a signal to the motor 65 to cause forward rotation of the motor 65 at, for example, a rate proportional to how hard the operator pulls back the firing trigger 20. The forward rotation of the motor 65 in turn causes the ring gear 78 at the distal end of the planetary gear assembly 72 to rotate, thereby causing the helical gear drum 80 to rotate, causing the ring 84 threaded on the helical gear drum 80 to travel distally along the helical gear drum 80. The rotation of the helical gear drum 80 also drives the main drive shaft assembly as described above, which in turn causes deployment of the knife 32 in the end effector 12. That is, the knife 32 and sled 33 are caused to traverse the channel 22 longitudinally, thereby cutting tissue clamped in the end effector 12. Also, the stapling operation of the end effector 12 is caused to happen in embodiments where a stapling-type end effector is used.

By the time the cutting/stapling operation of the end effector 12 is complete, the ring 84 on the helical gear drum 80 will have reached the distal end of the helical gear drum 80, thereby causing the reverse motor sensor 130 to be tripped, which sends a signal to the control unit which sends a signal to the motor 65 to cause the motor 65 to reverse its rotation. This in turn causes the knife 32 to retract, and also causes the ring 84 on the helical gear drum 80 to move back to the proximate end of the helical gear drum 80.

The middle handle piece 104 includes a backside shoulder 106 that engages the slotted arm 90 as best shown in FIGS. 8 and 9. The middle handle piece 104 also has a forward motion stop 107 that engages the firing trigger 20. The movement of the slotted arm 90 is controlled, as explained above, by rotation of the motor 65. When the slotted arm 90 rotates CCW as the ring 84 travels from the proximate end of the helical gear drum 80 to the distal end, the middle handle piece 104 will be free to rotate CCW. Thus, as the user draws in the firing trigger 20, the firing trigger 20 will engage the forward motion stop 107 of the middle handle piece 104, causing the middle handle piece 104 to rotate CCW. Due to the backside shoulder 106 engaging the slotted arm 90, however, the middle handle piece 104 will only be able to rotate CCW as far as the slotted arm 90 permits. In that way, if the motor 65 should stop rotating for some reason, the slotted arm 90 will stop rotating, and the user will not be able to further draw in the firing trigger 20 because the middle handle piece 104 will not be free to rotate CCW due to the slotted arm 90.

Components of an exemplary closure system for closing (or clamping) the anvil 24 of the end effector 12 by retracting the closure trigger 18 are also shown in FIGS. 7-10. In the illustrated embodiment, the closure system includes a yoke 250 connected to the closure trigger 18 by a pin 251 that is inserted through aligned openings in both the closure trigger 18 and the yoke 250. A pivot pin 252, about which the closure trigger 18 pivots, is inserted through another opening in the closure trigger 18 which is offset from where the pin 251 is inserted through the closure trigger 18. Thus, retraction of the closure trigger 18 causes the upper part of the closure trigger 18, to which the yoke 250 is attached via the pin 251, to rotate CCW. The distal end of the yoke 250 is connected, via a pin 254, to a first closure bracket 256. The first closure bracket 256 connects to a second closure bracket 258. Collectively, the closure brackets 256, 258 define an opening in which the proximate end of the proximate closure tube 40 (see FIG. 4) is seated and held such that longitudinal movement of the closure brackets 256, 258 causes longitudinal motion by the proximate closure tube 40. The instrument 10 also includes a closure rod 260 disposed inside the proximate closure tube 40. The closure rod 260 may include a window 261 into which a post 263 on one of the handle exterior pieces, such as exterior lower side piece 59 in the illustrated embodiment, is disposed to fixedly connect the closure rod 260 to the handle 6. In that way, the proximate closure tube 40 is capable of moving longitudinally relative to the closure rod 260. The closure rod 260 may also include a distal collar 267 that fits into a cavity 269 in proximate spine tube 46 and is retained therein by a cap 271 (see FIG. 4).

In operation, when the yoke 250 rotates due to retraction of the closure trigger 18, the closure brackets 256, 258 cause the proximate closure tube 40 to move distally (i.e., away from the handle end of the instrument 10), which causes the distal closure tube 42 to move distally, which causes the anvil 24 to rotate about the pivot point 25 into the clamped or closed position. When the closure trigger 18 is unlocked from the locked position, the proximate closure tube 40 is caused to slide proximately, which causes the distal closure tube 42 to slide proximately, which, by virtue of the tab 27 being inserted in the window 45 of the distal closure tube 42, causes the anvil 24 to pivot about the pivot point 25 into the open or unclamped position. In that way, by retracting and locking the closure trigger 18, an operator may clamp tissue between the anvil 24 and channel 22, and may unclamp the tissue following the cutting/stapling operation by unlocking the closure trigger 18 from the locked position.

The control unit (described further below) may receive the outputs from end-of-stroke and beginning-of-stroke sensors 130, 142 and the run-motor sensor 110, and may control the motor 65 based on the inputs. For example, when an operator initially pulls the firing trigger 20 after locking the closure trigger 18, the run-motor sensor 110 is actuated. If the staple cartridge 34 is present in the end effector 12, a cartridge lockout sensor (not shown) may be closed, in which case the control unit may output a control signal to the motor 65 to cause the motor 65 to rotate in the forward direction. When the end effector 12 reaches the end of its stroke, the reverse motor sensor 130 will be activated. The control unit may receive this output from the reverse motor sensor 130 and cause the motor 65 to reverse its rotational direction. When the knife 32 is fully retracted, the stop motor sensor switch 142 is activated, causing the control unit to stop the motor 65.

In other embodiments, rather than a proportional-type sensor 110, an on-off type sensor could be used. In such embodiments, the rate of rotation of the motor 65 would not be proportional to the force applied by the operator. Rather, the motor 65 would generally rotate at a constant rate. But the operator would still experience force feedback because the firing trigger 20 is geared into the gear drive train.

The instrument 10 may include a number of sensor transponders in the end effector 12 for sensing various conditions related to the end effector 12, such as sensor transponders for determining the status of the staple cartridge 34 (or other type of cartridge depending on the type of surgical instrument), the progress of the stapler during closure and firing, etc. The sensor transponders may be passively powered by inductive signals, as described further below, although in other embodiments the transponders could be powered by a remote power source, such as a battery in the end effector 12, for example. The sensor transponder(s) could include magnetoresistive, optical, electromechanical, RFID, MEMS, motion or pressure sensors, for example. These sensor transponders may be in communication with a control unit 300, which may be housed in the handle 6 of the instrument 10, for example, as shown in FIG. 11.

As shown in FIG. 12, according to various embodiments the control unit 300 may comprise a processor 306 and one or more memory units 308. By executing instruction code stored in the memory 308, the processor 306 may control various components of the instrument 10, such as the motor 65 or a user display (not shown), based on inputs received from the various end effector sensor transponders and other sensor(s) (such as the run-motor sensor 110, the end-of-stroke sensor 130, and the beginning-of-stroke sensor 142, for example). The control unit 300 may be powered by the battery 64 during surgical use of instrument 10. The control unit 300 may comprise an inductive element 302 (e.g., a coil or antenna) to pick up wireless signals from the sensor transponders, as described in more detail below. Input signals received by the inductive element 302 acting as a receiving antenna may be demodulated by a demodulator 310 and decoded by a decoder 312. The input signals may comprise data from the sensor transponders in the end effector 12, which the processor 306 may use to control various aspects of the instrument 10.

To transmit signals to the sensor transponders, the control unit 300 may comprise an encoder 316 for encoding the signals and a modulator 318 for modulating the signals according to the modulation scheme. The inductive element 302 may act as the transmitting antenna. The control unit 300 may communicate with the sensor transponders using any suitable wireless communication protocol and any suitable frequency (e.g., an ISM band). Also, the control unit 300 may transmit signals at a different frequency range than the frequency range of the received signals from the sensor transponders. Also, although only one antenna (inductive element 302) is shown in FIG. 12, in other embodiments the control unit 300 may have separate receiving and transmitting antennas.

According to various embodiments, the control unit 300 may comprise a microcontroller, a microprocessor, a field programmable gate array (FPGA), one or more other types of integrated circuits (e.g., RF receivers and PWM controllers), and/or discrete passive components. The control units may also be embodied as system-on-chip (SoC) or a system-in-package (SIP), for example.

As shown in FIG. 11, the control unit 300 may be housed in the handle 6 of the instrument 10 and one or more of the sensor transponders 368 for the instrument 10 may be located in the end effector 12. To deliver power and/or transmit data to or from the sensor transponders 368 in the end effector 12, the inductive element 302 of the control unit 300 may be inductively coupled to a secondary inductive element (e.g., a coil) 320 positioned in the shaft 8 distally from the rotation joint 29. The secondary inductive element 320 is preferably electrically insulated from the conductive shaft 8.

The secondary inductive element 320 may be connected by an electrically conductive, insulated wire 322 to a distal inductive element (e.g., a coil) 324 located near the end effector 12, and preferably distally relative to the articulation pivot 14. The wire 322 may be made of an electrically conductive polymer and/or metal (e.g., copper) and may be sufficiently flexible so that it could pass though the articulation pivot 14 and not be damaged by articulation. The distal inductive element 324 may be inductively coupled to the sensor transponder 368 in, for example, the cartridge 34 of the end effector 12. The transponder 368, as described in more detail below, may include an antenna (or coil) for inductive coupling to the distal coil 324, a sensor and integrated control electronics for receiving and transmitting wireless communication signals.

The transponder 368 may use a portion of the power of the inductive signal received from the distal inductive element 326 to passively power the transponder 368. Once sufficiently powered by the inductive signals, the transponder 368 may receive and transmit data to the control unit 300 in the handle 6 via (i) the inductive coupling between the transponder 368 and the distal inductive element 324, (ii) the wire 322, and (iii) the inductive coupling between the secondary inductive element 320 and the control unit 300. That way, the control unit 300 may communicate with the transponder 368 in the end effector 12 without a direct wired connection through complex mechanical joints like the rotating joint 29 and/or without a direct wired connection from the shaft 8 to the end effector 12, places where it may be difficult to maintain such a wired connection. In addition, because the distances between the inductive elements (e.g., the spacing between (i) the transponder 368 and the distal inductive element 324, and (ii) the secondary inductive element 320 and the control unit 300) and fixed and known, the couplings could be optimized for inductive transfer of energy. Also, the distances could be relatively short so that relatively low power signals could be used to thereby minimize interference with other systems in the use environment of the instrument 10.

In the embodiment of FIG. 12, the inductive element 302 of the control unit 300 is located relatively near to the control unit 300. According to other embodiments, as shown in FIG. 13, the inductive element 302 of the control unit 300 may be positioned closer to the rotating joint 29 to that it is closer to the secondary inductive element 320, thereby reducing the distance of the inductive coupling in such an embodiment. Alternatively, the control unit 300 (and hence the inductive element 302) could be positioned closer to the secondary inductive element 320 to reduce the spacing.

In other embodiments, more or fewer than two inductive couplings may be used. For example, in some embodiments, the surgical instrument 10 may use a single inductive coupling between the control unit 300 in the handle 6 and the transponder 368 in the end effector 12, thereby eliminating the inductive elements 320, 324 and the wire 322. Of course, in such an embodiment, a stronger signal may be required due to the greater distance between the control unit 300 in the handle 6 and the transponder 368 in the end effector 12. Also, more than two inductive couplings could be used. For example, if the surgical instrument 10 had numerous complex mechanical joints where it would be difficult to maintain a direct wired connection, inductive couplings could be used to span each such joint. For example, inductive couplers could be used on both sides of the rotary joint 29 and both sides of the articulation pivot 14, with the inductive element 321 on the distal side of the rotary joint 29 connected by a wire 322 to the inductive element 324 of the proximate side of the articulation pivot, and a wire 323 connecting the inductive elements 325, 326 on the distal side of the articulation pivot 14 as shown in FIG. 14. In this embodiment, the inductive element 326 may communicate with the sensor transponder 368.

In addition, the transponder 368 may include a number of different sensors. For example, it may include an array of sensors. Further, the end effector 12 could include a number of sensor transponders 368 in communication with the distal inductive element 324 (and hence the control unit 300). Also, the inductive elements 320, 324 may or may not include ferrite cores. As mentioned before, they are also preferably insulated from the electrically conductive outer shaft (or frame) of the instrument 10 (e.g., the closure tubes 40, 42), and the wire 322 is also preferably insulated from the outer shaft 8.

FIG. 15 is a diagram of an end effector 12 including a transponder 368 held or embedded in the cartridge 34 at the distal end of the channel 22. The transponder 368 may be connected to the cartridge 34 by a suitable bonding material, such as epoxy. In this embodiment, the transponder 368 includes a magnetoresistive sensor. The anvil 24 also includes a permanent magnet 369 at its distal end and generally facing the transponder 368. The end effector 12 also includes a permanent magnet 370 connected to the sled 33 in this example embodiment. This allows the transponder 368 to detect both opening/closing of the end effector 12 (due to the permanent magnet 369 moving further or closer to the transponder as the anvil 24 opens and closes) and completion of the stapling/cutting operation (due to the permanent magnet 370 moving toward the transponder 368 as the sled 33 traverses the channel 22 as part of the cutting operation).

FIG. 15 also shows the staples 380 and the staple drivers 382 of the staple cartridge 34. As explained previously, according to various embodiments, when the sled 33 traverses the channel 22, the sled 33 drives the staple drivers 382 which drive the staples 380 into the severed tissue held in the end effector 12, the staples 380 being formed against the anvil 24. As noted above, such a surgical cutting and fastening instrument is but one type of surgical instrument in which embodiments of the present application may be advantageously employed. Various embodiments of the present application may be used in any type of surgical instrument having one or more sensor transponders.

In the embodiments described above, the battery 64 powers (at least partially) the firing operation of the instrument 10. As such, the instrument may be a so-called “power-assist” device. More details and additional embodiments of power-assist devices are described in the '573 application, which is incorporated herein. It should be recognized, however, that the instrument 10 need not be a power-assist device and that this is merely an example of a type of device that may utilize aspects of embodiments of the present application. For example, the instrument 10 may include a user display (such as a LCD or LED display) that is powered by the battery 64 and controlled by the control unit 300. Data from the sensor transponders 368 in the end effector 12 may be displayed on such a display.

In another embodiment, the shaft 8 of the instrument 10, including for example, the proximate closure tube 40 and the distal closure tube 42, may collectively serve as part of an antenna for the control unit 300 by radiating signals to the sensor transponder 368 and receiving radiated signals from the sensor transponder 368. That way, signals to and from the remote sensor in the end effector 12 may be transmitted via the shaft 8 of the instrument 10.

The proximate closure tube 40 may be grounded at its proximate end by the exterior lower and upper side pieces 59-62, which may be made of a nonelectrically conductive material, such as plastic. The drive shaft assembly components (including the main drive shaft 48 and secondary drive shaft 50) inside the proximate and distal closure tubes 40, 42 may also be made of a nonelectrically conductive material, such as plastic. Further, components of end effector 12 (such as the anvil 24 and the channel 22) may be electrically coupled to (or in direct or indirect electrical contact with) the distal closure tube 42 such that they may also serve as part of the antenna. Further, the sensor transponder 368 could be positioned such that it is electrically insulated from the components of the shaft 8 and end effector 12 serving as the antenna. For example, the sensor transponder 368 may be positioned in the cartridge 34, which may be made of a nonelectrically conductive material, such as plastic. Because the distal end of the shaft 8 (such as the distal end of the distal closure tube 42) and the portions of the end effector 12 serving as the antenna may be relatively close in distance to the sensor 368, the power for the transmitted signals may be held at low levels, thereby minimizing or reducing interference with other systems in the use environment of the instrument 10.

In such an embodiment, as shown in FIG. 16, the control unit 300 may be electrically coupled to the shaft 8 of the instrument 10, such as to the proximate closure tube 40, by a conductive link 400 (e.g., a wire). Portions of the outer shaft 8, such as the closure tubes 40, 42, may therefore act as part of an antenna for the control unit 300 by radiating signals to the sensor 368 and receiving radiated signals from the sensor 368. Input signals received by the control unit 300 may be demodulated by the demodulator 310 and decoded by the decoder 312 (see FIG. 12). The input signals may comprise data from the sensors 368 in the end effector 12, which the processor 306 may use to control various aspects of the instrument 10, such as the motor 65 or a user display.

To transmit data signals to or from the sensors 368 in the end effector 12, the link 400 may connect the control unit 300 to components of the shaft 8 of the instrument 10, such as the proximate closure tube 40, which may be electrically connected to the distal closure tube 42. The distal closure tube 42 is preferably electrically insulated from the remote sensor 368, which may be positioned in the plastic cartridge 34 (see FIG. 3). As mentioned before, components of the end effector 12, such as the channel 22 and the anvil 24 (see FIG. 3), may be conductive and in electrical contact with the distal closure tube 42 such that they, too, may serve as part of the antenna.

With the shaft 8 acting as the antenna for the control unit 300, the control unit 300 can communicate with the sensor 368 in the end effector 12 without a direct wired connection. In addition, because the distances between shaft 8 and the remote sensor 368 is fixed and known, the power levels could be optimized for low levels to thereby minimize interference with other systems in the use environment of the instrument 10. The sensor 368 may include communication circuitry for radiating signals to the control unit 300 and for receiving signals from the control unit 300, as described above. The communication circuitry may be integrated with the sensor 368.

In another embodiment, the components of the shaft 8 and/or the end effector 12 may serve as an antenna for the remote sensor 368. In such an embodiment, the remote sensor 368 is electrically connected to the shaft (such as to distal closure tube 42, which may be electrically connected to the proximate closure tube 40) and the control unit 300 is insulated from the shaft 8. For example, the sensor 368 could be connected to a conductive component of the end effector 12 (such as the channel 22), which in turn may be connected to conductive components of the shaft (e.g., the closure tubes 40, 42). Alternatively, the end effector 12 may include a wire (not shown) that connects the remote sensor 368 the distal closure tube 42.

Typically, surgical instruments, such as the instrument 10, are cleaned and sterilized prior to use. In one sterilization technique, the instrument 10 is placed in a closed and sealed container 280, such as a plastic or TYVEK container or bag, as shown in FIGS. 17 and 18. The container and the instrument are then placed in a field of radiation that can penetrate the container, such as gamma radiation, x-rays, or high-energy electrons. The radiation kills bacteria on the instrument 10 and in the container 280. The sterilized instrument 10 can then be stored in the sterile container 280. The sealed, sterile container 280 keeps the instrument 10 sterile until it is opened in a medical facility or some other use environment. Instead of radiation, other means of sterilizing the instrument 10 may be used, such as ethylene oxide or steam.

When radiation, such as gamma radiation, is used to sterilize the instrument 10, components of the control unit 300, particularly the memory 308 and the processor 306, may be damaged and become unstable. Thus, according to various embodiments of the present application, the control unit 300 may be programmed after packaging and sterilization of the instrument 10.

As shown in FIG. 17, a remote programming device 320, which may be a handheld device, may be brought into wireless communication with the control unit 300. The remote programming device 320 may emit wireless signals that are received by the control unit 300 to program the control unit 300 and to power the control unit 300 during the programming operation. That way, the battery 64 does not need to power the control unit 300 during the programming operation. According to various embodiments, the programming code downloaded to the control unit 300 could be of relatively small size, such as 1 MB or less, so that a communications protocol with a relatively low data transmission rate could be used if desired. Also, the remote programming unit 320 could be brought into close physical proximity with the surgical instrument 10 so that a low power signal could be used.

Referring back to FIG. 19, the control unit 300 may comprise an inductive coil 402 to pick up wireless signals from a remote programming device 320. A portion of the received signal may be used by a power circuit 404 to power the control unit 300 when it is not being powered by the battery 64.

Input signals received by the coil 402 acting as a receiving antenna may be demodulated by a demodulator 410 and decoded by a decoder 412. The input signals may comprise programming instructions (e.g., code), which may be stored in a non-volatile memory portion of the memory 308. The processor 306 may execute the code when the instrument 10 is in operation. For example, the code may cause the processor 306 to output control signals to various sub-systems of the instrument 10, such as the motor 65, based on data received from the sensors 368.

The control unit 300 may also comprise a non-volatile memory unit 414 that comprises boot sequence code for execution by the processor 306. When the control unit 300 receives enough power from the signals from the remote control unit 320 during the post-sterilization programming operation, the processor 306 may first execute the boot sequence code (“boot loader”) 414, which may load the processor 306 with an operating system.

The control unit 300 may also send signals back to the remote programming unit 320, such as acknowledgement and handshake signals, for example. The control unit 300 may comprise an encoder 416 for encoding the signals to then be sent to the programming device 320 and a modulator 418 for modulating the signals according to the modulation scheme. The coil 402 may act as the transmitting antenna. The control unit 300 and the remote programming device 320 may communicate using any suitable wireless communication protocol (e.g., Bluetooth) and any suitable frequency (e.g., an ISM band). Also, the control unit 300 may transmit signals at a different frequency range than the frequency range of the received signals from the remote programming unit 320.

FIG. 20 is a simplified diagram of the remote programming device 320 according to various embodiments of the present application. As shown in FIG. 20, the remote programming unit 320 may comprise a main control board 230 and a boosted antenna board 232. The main control board 230 may comprise a controller 234, a power module 236, and a memory 238. The memory 238 may stored the operating instructions for the controller 234 as well as the programming instructions to be transmitted to the control unit 300 of the surgical instrument 10. The power module 236 may provide a stable DC voltage for the components of the remote programming device 320 from an internal battery (not shown) or an external AC or DC power source (not shown).

The boosted antenna board 232 may comprise a coupler circuit 240 that is in communication with the controller 234 via an I²C bus, for example. The coupler circuit 240 may communicate with the control unit 300 of the surgical instrument via an antenna 244. The coupler circuit 240 may handle the modulating/demodulating and encoding/decoding operations for transmissions with the control unit. According to other embodiments, the remote programming device 320 could have a discrete modulator, demodulator, encoder and decoder. As shown in FIG. 20, the boost antenna board 232 may also comprise a transmitting power amp 246, a matching circuit 248 for the antenna 244, and a filter/amplifier 249 for receiving signals.

According to other embodiments, as shown in FIG. 20, the remote programming device could be in communication with a computer device 460, such as a PC or a laptop, via a USB and/or RS232 interface, for example. In such a configuration, a memory of the computing device 460 may store the programming instructions to be transmitted to the control unit 300. In another embodiment, the computing device 460 could be configured with a wireless transmission system to transmit the programming instructions to the control unit 300.

In addition, according to other embodiments, rather than using inductive coupling between the control unit 300 and the remote programming device 320, capacitively coupling could be used. In such an embodiment, the control unit 300 could have a plate instead of a coil, as could the remote programming unit 320.

In another embodiment, rather than using a wireless communication link between the control unit 300 and the remote programming device 320, the programming device 320 may be physically connected to the control unit 300 while the instrument 10 is in its sterile container 280 in such a way that the instrument 10 remains sterilized. FIG. 21 is a diagram of a packaged instrument 10 according to such an embodiment. As shown in FIG. 22, the handle 6 of the instrument 10 may include an external connection interface 470. The container 280 may further comprise a connection interface 472 that mates with the external connection interface 470 of the instrument 10 when the instrument 10 is packaged in the container 280. The programming device 320 may include an external connection interface (not shown) that may connect to the connection interface 472 at the exterior of the container 280 to thereby provide a wired connection between the programming device 320 and the external connection interface 470 of the instrument 10.

FIGS. 23 and 24 depict a surgical cutting and fastening instrument 510 according to various embodiments of the present application. The illustrated embodiment is an endoscopic instrument and, in general, the embodiments of the instrument 510 described herein are endoscopic surgical cutting and fastening instruments. It should be noted, however, that according to other embodiments of the present application, the instrument may be a non-endoscopic surgical cutting and fastening instrument, such as a laparoscopic instrument.

The surgical instrument 510 depicted in FIGS. 23 and 24 comprises a handle 512, a shaft 514, and an articulating end effector 516 pivotally connected to the shaft 514 at an articulation pivot 518. Correct placement and orientation of the end effector 516 may be facilitated by controls on the handle 512, including (1) a rotation knob 517 for rotating the closure tube (described in more detail below in connection with FIGS. 25-26) at a free rotating joint 519 of the shaft 514 to thereby rotate the end effector 516 and (2) an articulation control 520 to effect rotational articulation of the end effector 516 about the articulation pivot 518. In the illustrated embodiment, the end effector 516 is configured to act as an endocutter for clamping, severing and stapling tissue, although, in other embodiments, different types of end effectors may be used, such as end effectors for other types of surgical devices, such as graspers, cutters, staplers, clip appliers, access devices, drug/gene therapy devices, ultrasound, RF or laser devices, etc.

The handle 512 of the instrument 510 may include a closure trigger 522 and a firing trigger 524 for actuating the end effector 516. It will be appreciated that instruments having end effectors directed to different surgical tasks may have different numbers or types of triggers or other suitable controls for operating the end effector 516. The end effector 516 is shown separated from the handle 512 by a preferably elongate shaft 514. In one embodiment, a clinician or operator of the instrument 510 may articulate the end effector 516 relative to the shaft 514 by utilizing the articulation control 520 as described in more detail in pending U.S. patent application Ser. No. 11/329,020 entitled “SURGICAL INSTRUMENT HAVING AN ARTICULATING END EFFECTOR” to Hueil et al., which is incorporated herein by reference.

The end effector 516 includes in this example, among other things, a staple channel 526 and a pivotally translatable clamping member, such as an anvil 528, which are maintained at a spacing that assures effective stapling and severing of tissue clamped in the end effector 516. The handle 512 includes a pistol grip 530 towards which a closure trigger 522 is pivotally drawn by the clinician to cause clamping or closing of the anvil 528 toward the staple channel 526 of the end effector 516 to thereby clamp tissue positioned between the anvil 528 and the channel 526. The firing trigger 524 is farther outboard of the closure trigger 522. Once the closure trigger 522 is locked in the closure position as further described below, the firing trigger 524 may rotate slightly toward the pistol grip 530 so that it can be reached by the operator using one hand. The operator may then pivotally draw the firing trigger 524 toward the pistol grip 530 to cause the stapling and severing of clamped tissue in the end effector 516. In other embodiments, different types of clamping members besides the anvil 528 may be used, such as, for example, an opposing jaw, etc.

It will be appreciated that the terms “proximal” and “distal” are used herein with reference to a clinician gripping the handle 512 of an instrument 510. Thus, the end effector 516 is distal with respect to the more proximal handle 512. It will be further appreciated that, for convenience and clarity, spatial terms such as “vertical” and “horizontal” are used herein with respect to the drawings. However, surgical instruments are used in many orientations and positions, and these terms are not intended to be limiting and absolute.

The closure trigger 522 may be actuated first. Once the clinician is satisfied with the positioning of the end effector 516, the clinician may draw back the closure trigger 522 to its fully closed, locked position proximate to the pistol grip 530. The firing trigger 524 may then be actuated. The firing trigger 524 returns to the open position (shown in FIGS. 23 and 24) when the clinician removes pressure, as described more fully below. A release button 532 on the handle 512, when depressed, may release the locked closure trigger 522. Various configurations for locking and unlocking the closure trigger 522 using the release button 532 are described in pending U.S. patent application Ser. No. 11/343,573 entitled “MOTOR-DRIVEN SURGICAL CUTTING AND FASTENING INSTRUMENT WITH LOADING FORCE FEEDBACK” to Shelton, IV et al., which is incorporated herein by reference.

FIG. 25A is an exploded view of the end effector 516 according to various embodiments, and FIG. 25B is a perspective view of the cutting instrument of FIG. 25A. As shown in the illustrated embodiment, the end effector 516 may include, in addition to the previously-mentioned channel 526 and anvil 528, a cutting instrument 534, a staple cartridge 538 that is removably seated (e.g., installed) in the channel 526, a sled 536 disposed within the staple cartridge 538, and a helical screw shaft 540.

The anvil 528 may be pivotably opened and closed at a pivot point 542 connected to the proximate end of the channel 526. The anvil 528 may also include a tab 544 at its proximate end that is inserted into a component of the mechanical closure system (described further below) to open and close the anvil 528. When the closure trigger 522 is actuated, that is, drawn in by an operator of the instrument 510, the anvil 528 may pivot about the pivot point 542 into the clamped or closed position. If clamping of the end effector 516 is satisfactory, the operator may actuate the firing trigger 524, which, as explained in more detail below, causes the cutting instrument 534 to travel longitudinally along the channel 526.

As shown, the cutting instrument 534 includes upper guide pins 546 that enter an anvil slot 548 in the anvil 528 to verify and assist in maintaining the anvil 528 in a closed state during staple formation and severing. Spacing between the channel 526 and anvil 528 is further maintained by the cutting instrument 534 by having middle pins 550 slide along the top surface of the channel 526 while a bottom foot 552 opposingly slides along the undersurface of the channel 526, guided by a longitudinal opening 554 in the channel 526. A distally presented cutting surface 556 between the upper guide pins 546 and middle pins 550 severs clamped tissue while distally-presented surface 558 actuates the staple cartridge 538 by engaging and progressively driving the sled 536 through the staple cartridge 538 from an unfired position located at a proximal end of the staple cartridge 538 to a fired position located at a distal end of the staple cartridge 538. When the sled 536 is in the unfired position, the staple cartridge 538 is in an unfired, or unspent, state. When the sled 536 is in the fired position, the staple cartridge 538 is in a fired, or spent, state. Actuation of the staple cartridge 538 causes staple drivers 560 to cam upwardly, driving staples 562 out of upwardly open staple holes 564 formed in the staple cartridge 538. The staples 562 are subsequently formed against a staple forming undersurface 566 of the anvil 528. A staple cartridge tray 568 encompasses from the bottom the other components of the staple cartridge 538 to hold them in place. The staple cartridge tray 568 includes a rearwardly open slot 570 that overlies the longitudinal opening 554 in the channel 526. A lower surface of the staple cartridge 538 and an upward surface of the channel 526 form a firing drive slot 700 (FIG. 28) through which the middle pins 550 pass during distal and proximal movement of the cutting instrument 534. The sled 536 may be an integral component of the staple cartridge 538 such that when the cutting instrument 534 retracts following the cutting operation, the sled 536 does not retract. U.S. Pat. No. 6,978,921, entitled “SURGICAL STAPLING INSTRUMENT INCORPORATING AN E-BEAM FIRING MECHANISM” to Shelton, IV et al., which is incorporated herein by reference, provides more details about such two-stroke cutting and fastening instruments.

It should be noted that although the embodiments of the instrument 510 described herein employ an end effector 516 that staples the severed tissue, in other embodiments different techniques for fastening or sealing the severed tissue may be used. For example, end effectors that use RF energy or adhesives to fasten the severed tissue may also be used. U.S. Pat. No. 5,709,680 entitled “ELECTROSURGICAL HEMOSTATIC DEVICE” to Yates et al., and U.S. Pat. No. 5,688,270 entitled “ELECTOSURGICAL HEMOSTATIC DEVICE WITH RECESSED AND/OR OFFSET ELECTRODES” to Yates et al., both of which are incorporated herein by reference, disclose cutting instruments that uses RF energy to fasten the severed tissue. U.S. patent application Ser. No. 11/267,811 entitled “SURGICAL STAPLING INSTRUMENTS STRUCTURED FOR DELIVERY OF MEDICAL AGENTS” to Morgan et al., and U.S. patent application Ser. No. 11/267,383 entitled “SURGICAL STAPLING INSTRUMENTS STRUCTURED FOR PUMP-ASSISTED DELIVERY OF MEDICAL AGENTS” to Shelton IV et al., both of which are also incorporated herein by reference, disclose cutting instruments that uses adhesives to fasten the severed tissue. Accordingly, although the description herein refers to cutting/stapling operations and the like, it should be recognized that this is an exemplary embodiment and is not meant to be limiting. Other tissue-fastening techniques may also be used.

FIGS. 26 and 27 are exploded views and FIG. 28 is a side view of the end effector 516 and shaft 514 according to various embodiments. As shown in the illustrated embodiment, the shaft 514 may include a proximate closure tube 572 and a distal closure tube 574 pivotably linked by a pivot links 576. The distal closure tube 574 includes an opening 578 into which the tab 544 on the anvil 528 is inserted in order to open and close the anvil 528, as further described below. Disposed inside the closure tubes 572, 574 may be a proximate spine tube 579. Disposed inside the proximate spine tube 579 may be a main rotational (or proximate) drive shaft 580 that communicates with a secondary (or distal) drive shaft 582 via a bevel gear assembly 584. The secondary drive shaft 582 is connected to a drive gear 586 that engages a proximate drive gear 588 of the helical screw shaft 540. The vertical bevel gear 584 b may sit and pivot in an opening 590 in the distal end of the proximate spine tube 579. A distal spine tube 592 may be used to enclose the secondary drive shaft 582 and the drive gears 586, 588. Collectively, the main drive shaft 580, the secondary drive shaft 582, and the articulation assembly (e.g., the bevel gear assembly 584 a-c) are sometimes referred to herein as the “main drive shaft assembly.”

A bearing 594, positioned at a distal end of the staple channel 526, receives the helical drive screw 540, allowing the helical drive screw 540 to freely rotate with respect to the channel 526. The helical screw shaft 540 may interface a threaded opening (not shown) of the cutting instrument 534 such that rotation of the shaft 540 causes the cutting instrument 534 to translate distally or proximately (depending on the direction of the rotation) through the staple channel 526. Accordingly, when the main drive shaft 580 is caused to rotate by actuation of the firing trigger 524 (as explained in further detail below), the bevel gear assembly 584 a-c causes the secondary drive shaft 582 to rotate, which in turn, because of the engagement of the drive gears 586, 588, causes the helical screw shaft 540 to rotate, which causes the cutting instrument 534 to travel longitudinally along the channel 526 to cut any tissue clamped within the end effector 516. The sled 536 may be made of, for example, plastic, and may have a sloped distal surface. As the sled 536 traverses the channel 526, the sloped distal surface may cam the staple drivers 560 upward, which in turn push up or drive the staples 562 in the staple cartridge 538 through the clamped tissue and against the staple forming undersurface 566 of the anvil 528, thereby stapling the severed tissue. When the cutting instrument 534 is retracted, the cutting instrument 534 and the sled 536 may become disengaged, thereby leaving the sled 536 at the distal end of the channel 526.

FIGS. 29-32 illustrate an exemplary embodiment of a motor-driven endocutter, and in particular the handle 512 thereof, that provides operator-feedback regarding the deployment and loading force of the cutting instrument 534 in the end effector 516. In addition, the embodiment may use power provided by the operator in retracting the firing trigger 524 to power the device (a so-called “power assist” mode). As shown in the illustrated embodiment, the handle 512 includes exterior lower side pieces 596, 598 and exterior upper side pieces 600, 602 that fit together to form, in general, the exterior of the handle 512. A battery 604 may be provided in the pistol grip portion 530 of the handle 512. The battery 564 may be constructed according to any suitable construction or chemistry including, for example, a Li-ion chemistry such as LiCoO2 or LiNiO2, a Nickel Metal Hydride chemistry, etc. The battery 604 powers a motor 606 disposed in an upper portion of the pistol grip portion 530 of the handle 512. According to various embodiments, the motor 606 may be a DC brushed driving motor having a maximum rotation of approximately 5000 to 100,000 RPM. The motor 606 may drive a 90-degree bevel gear assembly 608 comprising a first bevel gear 610 and a second bevel gear 612. The bevel gear assembly 608 may drive a planetary gear assembly 614. The planetary gear assembly 614 may include a pinion gear 616 connected to a drive shaft 618. The pinion gear 616 may drive a mating ring gear 620 that drives a helical gear drum 622 via a drive shaft 624. A ring 626 may be threaded on the helical gear drum 622. Thus, when the motor 606 rotates, the ring 626 is caused to travel along the helical gear drum 622 by means of the interposed bevel gear assembly 608, planetary gear assembly 614 and ring gear 620.

The handle 512 may also include a run motor sensor 628 in communication with the firing trigger 524 to detect when the firing trigger 524 has been drawn in (or “closed”) toward the pistol grip portion 530 of the handle 512 by the operator to thereby actuate the cutting/stapling operation by the end effector 516. The sensor 628 may be a proportional sensor such as, for example, a rheostat or variable resistor. When the firing trigger 524 is drawn in, the sensor 628 detects the movement, and sends an electrical signal indicative of the voltage (or power) to be supplied to the motor 606. When the sensor 628 is a variable resistor or the like, the rotation of the motor 606 may be generally proportional to the amount of movement of the firing trigger 524. That is, if the operator only draws or closes the firing trigger 524 in a little bit, the rotation of the motor 606 is relatively low. When the firing trigger 524 is fully drawn in (or in the fully closed position), the rotation of the motor 606 is at its maximum. In other words, the harder the operator pulls on the firing trigger 524, the more voltage is applied to the motor 606, causing a greater rate of rotation. In another embodiment, for example, the control unit (described further below) may output a PWM control signal to the motor 606 based on the input from the sensor 628 in order to control the motor 606.

The handle 512 may include a middle handle piece 630 adjacent to the upper portion of the firing trigger 524. The handle 512 also may comprise a bias spring 632 connected between posts on the middle handle piece 630 and the firing trigger 524. The bias spring 632 may bias the firing trigger 524 to its fully open position. In that way, when the operator releases the firing trigger 524, the bias spring 632 will pull the firing trigger 524 to its open position, thereby removing actuation of the sensor 628, thereby stopping rotation of the motor 606. Moreover, by virtue of the bias spring 632, any time an operator closes the firing trigger 524, the operator will experience resistance to the closing operation, thereby providing the operator with feedback as to the amount of rotation exerted by the motor 606. Further, the operator could stop retracting the firing trigger 524 to thereby remove force from the sensor 628, to thereby stop the motor 606. As such, the operator may stop the deployment of the end effector 516, thereby providing a measure of control of the cutting/fastening operation to the operator.

The distal end of the helical gear drum 622 includes a distal drive shaft 634 that drives a ring gear 636, which mates with a pinion gear 638. The pinion gear 638 is connected to the main drive shaft 580 of the main drive shaft assembly. In that way, rotation of the motor 606 causes the main drive shaft assembly to rotate, which causes actuation of the end effector 516, as described above.

The ring 626 threaded on the helical gear drum 622 may include a post 640 that is disposed within a slot 642 of a slotted arm 644. The slotted arm 644 has an opening 646 its opposite end 648 that receives a pivot pin 650 that is connected between the handle exterior side pieces 596, 598. The pivot pin 650 is also disposed through an opening 652 in the firing trigger 524 and an opening 654 in the middle handle piece 630.

In addition, the handle 512 may include a reverse motor (or end-of-stroke) sensor 656 and a stop motor (or beginning-of-stroke) sensor 658. In various embodiments, the reverse motor sensor 656 may be a normally-open limit switch located at the distal end of the helical gear drum 622 such that the ring 626 threaded on the helical gear drum 622 contacts and closes the reverse motor sensor 656 when the ring 626 reaches the distal end of the helical gear drum 622. The reverse motor sensor 656, when closed, sends a signal to the control unit which sends a signal to the motor 606 to reverse its rotation direction, thereby withdrawing the cutting instrument of the end effector 516 following the cutting operation.

The stop motor sensor 658 may be, for example, a normally-closed limit switch. In various embodiments, it may be located at the proximate end of the helical gear drum 622 so that the ring 626 opens the switch 658 when the ring 626 reaches the proximate end of the helical gear drum 122.

In operation, when an operator of the instrument 510 pulls back the firing trigger 524, the sensor 628 detects the deployment of the firing trigger 524 and sends a signal to the control unit which sends a signal to the motor 606 to cause forward rotation of the motor 606 at, for example, a rate proportional to how hard the operator pulls back the firing trigger 524. The forward rotation of the motor 606 in turn causes the ring gear 620 at the distal end of the planetary gear assembly 614 to rotate, thereby causing the helical gear drum 622 to rotate, causing the ring 626 threaded on the helical gear drum 622 to travel distally along the helical gear drum 622. The rotation of the helical gear drum 622 also drives the main drive shaft assembly as described above, which in turn causes deployment of the cutting instrument 534 in the end effector 616. That is, the cutting instrument 534 and sled 536 are caused to traverse the channel 526 longitudinally, thereby cutting tissue clamped in the end effector 516. Also, the stapling operation of the end effector 516 is caused to happen in embodiments where a stapling-type end effector is used.

By the time the cutting/stapling operation of the end effector 516 is complete, the ring 526 on the helical gear drum 622 will have reached the distal end of the helical gear drum 622, thereby causing the reverse motor sensor 656 to be actuated, which sends a signal to the control unit which sends a signal to the motor 606 to cause the motor 606 to reverse its rotation. This in turn causes the cutting instrument 534 to retract, and also causes the ring 626 on the helical gear drum 622 to move back to the proximate end of the helical gear drum 622.

The middle handle piece 630 includes a backside shoulder 660 that engages the slotted arm 644 as best shown in FIGS. 30 and 31. The middle handle piece 630 also has a forward motion stop 662 that engages the firing trigger 524. The movement of the slotted arm 644 is controlled, as explained above, by rotation of the motor 606. When the slotted arm 644 rotates CCW as the ring 626 travels from the proximate end of the helical gear drum 622 to the distal end, the middle handle piece 630 will be free to rotate CCW. Thus, as the operator draws in the firing trigger 524, the firing trigger 524 will engage the forward motion stop 662 of the middle handle piece 630, causing the middle handle piece 630 to rotate CCW. Due to the backside shoulder 660 engaging the slotted arm 644, however, the middle handle piece 630 will only be able to rotate CCW as far as the slotted arm 644 permits. In that way, if the motor 606 should stop rotating for some reason, the slotted arm 644 will stop rotating, and the operator will not be able to further draw in the firing trigger 524 because the middle handle piece 630 will not be free to rotate CCW due to the slotted arm 644.

FIGS. 33 and 34 illustrate two states of a variable sensor that may be used as the run motor sensor 628 according to various embodiments of the present application. The sensor 628 may include a face portion 664, a first electrode (A) 666, a second electrode (B) 668, and a compressible dielectric material 670 (e.g., EAP) between the electrodes 666, 668. The sensor 628 may be positioned such that the face portion 664 contacts the firing trigger 524 when retracted. Accordingly, when the firing trigger 524 is retracted, the dielectric material 670 is compressed, as shown in FIG. 34, such that the electrodes 666, 668 are closer together. Since the distance “b” between the electrodes 666, 668 is directly related to the impedance between the electrodes 666, 668, the greater the distance the more impedance, and the closer the distance the less impedance. In that way, the amount that the dielectric material 670 is compressed due to retraction of the firing trigger 524 (denoted as force “F” in FIG. 34) is proportional to the impedance between the electrodes 666, 668. This impedance provided by the sensor 628 may be used with suitable signal conditioning circuitry to proportionally control the speed of the motor 606, for example.

Components of an exemplary closure system for closing (or clamping) the anvil 528 of the end effector 516 by retracting the closure trigger 522 are also shown in FIGS. 29-32. In the illustrated embodiment, the closure system includes a yoke 672 connected to the closure trigger 522 by a pin 674 that is inserted through aligned openings in both the closure trigger 522 and the yoke 672. A pivot pin 676, about which the closure trigger 522 pivots, is inserted through another opening in the closure trigger 522 which is offset from where the pin 674 is inserted through the closure trigger 622. Thus, retraction of the closure trigger 622 causes the upper part of the closure trigger 622, to which the yoke 672 is attached via the pin 674, to rotate CCW. The distal end of the yoke 672 is connected, via a pin 678, to a first closure bracket 680. The first closure bracket 680 connects to a second closure bracket 682. Collectively, the closure brackets 680, 682 define an opening in which the proximal end of the proximate closure tube 572 (see FIG. 26) is seated and held such that longitudinal movement of the closure brackets 680, 682 causes longitudinal motion by the proximate closure tube 572. The instrument 510 also includes a closure rod 684 disposed inside the proximate closure tube 572. The closure rod 684 may include a window 686 into which a post 688 on one of the handle exterior pieces, such as exterior lower side piece 596 in the illustrated embodiment, is disposed to fixedly connect the closure rod 684 to the handle 512. In that way, the proximate closure tube 572 is capable of moving longitudinally relative to the closure rod 684. The closure rod 684 may also include a distal collar 690 that fits into a cavity 692 in proximate spine tube 579 and is retained therein by a cap 694 (see FIG. 26).

In operation, when the yoke 672 rotates due to retraction of the closure trigger 522, the closure brackets 680, 682 cause the proximate closure tube 572 to move distally (i.e., away from the handle 512 of the instrument 510), which causes the distal closure tube 574 to move distally, which causes the anvil 528 to rotate about the pivot point 542 into the clamped or closed position. When the closure trigger 522 is unlocked from the locked position, the proximate closure tube 572 is caused to slide proximally, which causes the distal closure tube 574 to slide proximally, which, by virtue of the tab 544 being inserted in the opening 578 of the distal closure tube 574, causes the anvil 528 to pivot about the pivot point 542 into the open or unclamped position. In that way, by retracting and locking the closure trigger 252, an operator may clamp tissue between the anvil 528 and channel 526, and may unclamp the tissue following the cutting/stapling operation by unlocking the closure trigger 522 from the locked position.

The control unit (described further below) may receive the outputs from end-of-stroke and beginning-of-stroke sensors 656, 658 and the run-motor sensor 628, and may control the motor 606 based on the inputs. For example, when an operator initially pulls the firing trigger 524 after locking the closure trigger 522, the run-motor sensor 128 is actuated. If the control unit determines that an unspent staple cartridge 538 is present in the end effector 516, as described further below, the control unit may output a control signal to the motor 606 to cause the motor 606 to rotate in the forward direction. When the end effector 516 reaches the end of its stroke, the reverse motor sensor 656 will be activated. The control unit may receive this output from the reverse motor sensor 656 and cause the motor 606 to reverse its rotational direction. When the cutting instrument 534 is fully retracted, the stop motor sensor switch 658 is activated, causing the control unit to stop the motor 606.

According to various embodiments, the instrument 510 may include a transponder in the end effector 516. The transponder may generally be any device suitable for transmitting a wireless signal(s) indicating one or more conditions of the end effector 516. In certain embodiments, for example, wireless signals may be transmitted by the transponder to the control unit responsive to wireless signals received from the control unit. In such embodiments, the wireless signals transmitted by the control unit and the transponder are referred to as “interrogation” and “reply” signals, respectively. The transponder may be in communication with one or more types of sensors (e.g., position sensors, displacement sensors, pressure/load sensors, proximity sensors, etc.) located in the end effector 516 for transducing various end effector conditions such as, for example, a state of the staple cartridge 538 (e.g., fired or unfired) and the respective positions of the anvil 528 (e.g., open or closed) and the sled 536 (e.g., proximal or distal). Placement of sensors to determine such conditions is described in pending U.S. patent application Ser. No. 11/343,439 referenced above, which is incorporated herein. According to various embodiments and as discussed below, the transponder may be a passive device such that its operating power is derived from wireless signals (e.g., interrogation signals). In other embodiments, the transponder may be an active device powered by a self-contained power source (e.g., a battery) disposed within the end effector 516. The transponder and the control circuit may be configured to communicate using any suitable type of wireless signal. According to various embodiments and as discussed below, for example, the transponder and the control circuit may transmit and receive wireless signals using magnetic fields generated by inductive effects. It will be appreciated that the transponder and the control circuit may instead transmit and receive wireless signals using electromagnetic fields (e.g., RF signals, optical signals), or using electric fields generated by capacitive effects, for example. It will further be appreciated that the end effector 516 may include additional transponders, with each transponder having one more dedicated sensors for inputting data thereto.

FIG. 35 illustrates a block diagram of the control unit 696 according to various embodiments. As shown, the control unit 696 may comprise a processor 698 and one or more memory units 700. The control unit 696 may be powered by the battery 604 or other suitable power source contained within the instrument 510. In certain embodiments, the control unit 696 may further comprise an inductive element 702 (e.g., a coil or antenna) to transmit and receive wireless signals (e.g., interrogation and reply signals) from the transponder via magnetic fields. Signals received by the inductive element 702 may be demodulated by a demodulator 704 and decoded by a decoder 706. By executing instruction code stored in the memory 700, the processor 698 may control various components of the instrument 510, such as the motor 606 and a user display (not shown), based on inputs of the end effector sensors (as indicated by the decoded signals) and inputs received from other various sensor(s) (such as the run-motor sensor 628, the end-of-stroke and beginning-of-stroke sensors 656, 658, for example).

Wireless signals output by the control unit 696 may be in the form of alternating magnetic fields emitted by the inductive element 702. The control unit 696 may comprise an encoder 708 for encoding data to be transmitted to the transponder and a modulator 710 for modulating the magnetic field based on the encoded data using a suitable modulation scheme. The control unit 696 may communicate with the transponder using any suitable wireless communication protocol and any suitable frequency (e.g., an ISM band or other RF band). Also, the control unit 696 may transmit signals at a different frequency range than the frequency range of the reply signals received from the transponder. Additionally, although only one antenna (inductive element 702) is shown in FIG. 35, in other embodiments the control unit 696 may have separate receiving and transmitting antennas.

According to various embodiments, the control unit 696 may comprise a microcontroller, a microprocessor, a field programmable gate array (FPGA), one or more other types of integrated circuits (e.g., RF receivers and PWM controllers), and/or discrete passive components. The control unit 696 may also be embodied as system-on-chip (SoC) or a system-in-package (SIP), for example.

As shown in FIG. 37, the control unit 696 may be housed in the handle 512 of the instrument 510 and the transponder 712 may be located in the end effector 516. To transmit signals to the transponder 712 and receive signals therefrom, the inductive element 702 of the control unit 696 may be inductively coupled to a secondary inductive element (e.g., a coil) 714 positioned in the shaft 514 distally from the rotation joint 519. The secondary inductive element 714 is preferably electrically insulated from the conductive shaft 514.

The secondary inductive element 714 may be connected by an electrically conductive, insulated wire 716 to a distal inductive element (e.g., a coil) 718 located near the end effector 516, and preferably distally located relative to the articulation pivot 518. The wire 716 may be made of an electrically conductive polymer and/or metal (e.g., copper) and may be sufficiently flexible so that it could pass though the articulation pivot 518 and not be damaged by articulation. The distal inductive element 618 may be inductively coupled to the transponder 612 in, for example, the staple cartridge 538 of the end effector 516. The transponder 712, as described in more detail below, may include an antenna (or coil) for inductively coupling to the distal coil 718, as well as associated circuitry for transmitting and receiving wireless signals.

In certain embodiments, the transponder 712 may be passively powered by magnetic fields emitted by the distal inductive element 718. Once sufficiently powered, the transponder 712 may transmit and/or receive data (e.g., by modulating the magnetic fields) to the control unit 696 in the handle 512 via (i) the inductive coupling between the transponder 712 and the distal inductive element 718, (ii) the wire 716, and (iii) the inductive coupling between the secondary inductive element 714 and the control unit 696. The control unit 696 may thus communicate with the transponder 712 in the end effector 516 without a hardwired connection through complex mechanical joints like the rotating joint 519 and/or without a hardwired connection from the shaft 514 to the end effector 516, places where it may be difficult to maintain such connections. In addition, because the distances between the inductive elements (e.g., the spacing between (i) the transponder 712 and the distal inductive element 718, and (ii) the secondary inductive element 714 and the control unit 696) are fixed and known, the couplings could be optimized for inductive energy transfer. Also, the distances could be relatively short so that relatively low power signals could be used to thereby minimize interference with other systems in the use environment of the instrument 510.

In the embodiment of FIG. 36, the inductive element 702 of the control unit 696 is located relatively near to the control unit 696. According to other embodiments, as shown in FIG. 37, the inductive element 702 of the control unit 696 may be positioned closer to the rotating joint 519 to that it is closer to the secondary inductive element 714, thereby reducing the distance of the inductive coupling in such an embodiment. Alternatively, the control unit 696 (and hence the inductive element 702) could be positioned closer to the secondary inductive element 714 to reduce the spacing.

In other embodiments, more or fewer than two inductive couplings may be used. For example, in some embodiments, the surgical instrument 510 may use a single inductive coupling between the control unit 696 in the handle 512 and the transponder 712 in the end effector 516, thereby eliminating the inductive elements 714, 718 and the wire 716. Of course, in such an embodiment, stronger signals may be required due to the greater distance between the control unit 696 in the handle 512 and the transponder 712 in the end effector 516. Also, more than two inductive couplings could be used. For example, if the surgical instrument 510 had numerous complex mechanical joints where it would be difficult to maintain a hardwired connection, inductive couplings could be used to span each such joint. For example, inductive couplings could be used on both sides of the rotary joint 519 and both sides of the articulation pivot 518, with an inductive element 720 on the distal side of the rotary joint 519 connected by the wire 716 to the inductive element 718 of the proximate side of the articulation pivot, and a wire 722 connecting inductive elements 724, 726 on the distal side of the articulation pivot 518 as shown in FIG. 38. In this embodiment, the inductive element 726 may communicate with the transponder 712.

In the above-described embodiments, each of the inductive elements 702, 714, 718, 724, 726 may or may not include ferrite cores. Additionally, the inductive elements 714, 718, 724, 726 are also preferably insulated from the electrically conductive outer shaft (or frame) of the instrument 31 (e.g., the closure tubes 572, 574), and the wires 716, 722 are also preferably insulated from the outer shaft 514.

FIG. 39 is a bottom view of a portion of the staple cartridge 538 including the transponder 712 according to various embodiments. As shown, the transponder 712 may be held or embedded in the staple cartridge 538 at its distal end using a suitable bonding material, such as epoxy.

FIG. 40 illustrates a circuit diagram of the transponder 712 according to various embodiments. As shown, the transponder 712 may include a resonant circuit 749 comprising an inductive element 750 (e.g., a coil or antenna) and a capacitor 752. The transponder 712 may further include a microchip 754 coupled to the resonant circuit 749. In certain embodiments, the microchip 754 may be, for example, an RFID device containing circuitry for enabling communication with the control unit 196 via the inductive element 750 of the resonant circuit 749. The microchip 754 may include at least one data input for receiving data in the form of discrete or analog signals from the sensors 735 disposed in the end effector 516. As discussed above, the sensors 735 may include, for example, position sensors, displacement sensors, pressure/load sensors, proximity sensors for sensing various end effector conditions. The microchip 754 also may include one or more dynamic memory devices 755 (e.g., flash memory devices) for storing data transmitted from, for example, the control unit 696. The microchip 754 may further include one or more non-dynamic memory devices 757 (e.g., write-once memory devices) for storing static data, such as, for example, a staple cartridge identification number, manufacturer information, and information pertaining to physical characteristics of the staple cartridge 538.

In response to alternating magnetic fields emitted by the distal inductive element 718, the resonant circuit 749 of the transponder 712 is caused to resonate, thereby causing an alternating input voltage to be applied to the microchip 754. The resonant circuit 749 may have a resonant frequency given by

${f_{r} = \frac{1}{2\pi \sqrt{L_{1}C_{1}}}},$

where L₁ is the inductance value of the inductive element 750 and C₁ is the capacitance value of the capacitor 752. The values of L₁ and C₁ may be selected such that the resonant frequency of the circuit 749 is equal or nearly equal to the frequency of magnetic field transmitted by the distal inductive element 718. The circuitry of the microchip 754 may include a rectifying circuitry (not shown) for rectifying and conditioning the alternating input voltage to provide a DC voltage sufficient to power the microchip 754. Once powered, the microchip 754 may selectively load the inductive element 750 based on data received from the sensors 735 and the data stored in the memory devices 755, 757, thus modulating the magnetic fields coupling the distal inductive element 718 and the inductive element 750. The modulation of the magnetic field modulates the voltage across the distal inductive element 718, which in turn modulates the voltage across the inductive element 702 of the control unit 696. The control unit 696 may demodulate and decode the voltage signal across the inductive element 702 to extract data communicated by the microchip 754. The control unit 696 may process the data to verify, among other things, that the staple cartridge 538 is compatible with the instrument 510 and that end effector conditions are suitable for conducting a firing operation. Subsequent to verification of the data, the control unit 696 may enable a firing operation.

According to various embodiments, the resonant circuit 749 may further include a fuse 756 connected in series with the inductive element 750. When the fuse 756 is closed (e.g., conductive), the inductive element 750 is electrically coupled to the resonant circuit 749, thus enabling the transponder 712 to function as described above in response to an alternating magnetic field emitted by the distal inductive element 718. The closed state of the fuse 756 thus corresponds to an enabled state of the transponder 712. When the fuse 756 is opened (e.g., non-conductive), the inductive element 750 is electrically disconnected from the resonant circuit 749, thus preventing the resonant circuit 749 from generating the voltage necessary to operate the microchip 754. The open state of the fuse 756 thus corresponds to a disabled state of the transponder 712. The placement of the fuse 756 in FIG. 40 is shown by way of example only, and it will be appreciated that the fuse 756 may be connected in any manner such that the transponder 712 is disabled when the fuse 756 is opened.

According to various embodiments, the fuse 756 may be actuated (e.g., transitioned from closed to opened) substantially simultaneously with a firing operation of the instrument 510. For example, the fuse 756 may be actuated immediately before, during, or immediately after a firing operation. Actuation of the fuse 756 thus transitions the transponder 712 from the enabled state to the disabled state. Accordingly, if an attempt is made to reuse the staple cartridge 538, the transponder 712 will be unable to communicate data in response to a wireless signal transmitted by the distal inductive element 718. Based upon the absence of this data, the control unit 696 may determine that the transponder 712 is in a disabled state indicative of the fired state of the staple cartridge 538 and prevent a firing operation from being enabled. Thus, actuation of the fuse 756 prevents reuse of a staple cartridge 738 when the staple cartridge 738 is in the fired state.

In certain embodiments, the fuse 756 may be a mechanically-actuated fuse that is opened in response to movement of the cutting instrument 534 when actuated, for example. As shown in FIG. 41, for example, the fuse 756 may include a section of wire extending transversely across a longitudinal slot 758 of the staple cartridge 538 through which the cutting instrument 534 passes during a firing operation. When the instrument 510 is fired, the distal movement of the cutting instrument 534 severs the fuse 756, thus transitioning the transponder 717 to the disabled state so that it cannot be reused.

According to other embodiments, the fuse 756 may be an electrically-actuated fuse. For example, subsequent to receiving data from the transponder 712 and verifying that the end effector 516 is in a condition to be fired, the control unit 696 may transmit a wireless signal to the transponder 712 such that the resulting current flow through fuse 756 is sufficient to cause the fuse 756 to open. It will be appreciated that the strength of the wireless signal needed to open the fuse 756 may be different in amplitude, frequency, and duration than that used to communicate with the transponder 712. Additionally, it will be appreciated that other electrically-actuated components may be used instead of an electrically-actuated fuse to disable the transponder 712. For example, the control unit 696 may transmit a wireless signal to the transponder 712 such that resulting voltage developed across the resonant circuit 756 sufficiently exceeds the voltage rating of the capacitor 752 and/or circuitry of the microchip 754 to cause their destruction.

As an alternative to using an electrically-actuated fuse, the fuse 756 may instead be a thermally-actuated fuse (e.g., a thermal cutoff fuse) that is caused to open in response to heat generated by the flow of excessive current therethrough.

In certain cases, it may be desirable to communicate with the transponder 712 when the staple cartridge 538 is in the fired state. In such cases, it is not possible to entirely disable the transponder 712 as described in the embodiments above. FIG. 42 illustrates a circuit diagram of the transponder 712 according to various embodiments for enabling wireless communication with the control unit 696 when the staple cartridge 538 is in the fired state. As shown, the resonant circuit 749 of the transponder 712 may include a second capacitor 760 in parallel with the capacitor 752. The fuse 756 may be connected in series with the second capacitor 760 such that the resonant frequency of the resonant circuit 749 is determined by the open/closed state of the fuse 756. In particular, when the fuse 756 is closed, the resonant frequency is given by

${f_{r} = \frac{1}{2\pi \sqrt{L_{1}\left( {C_{1} + C_{2}} \right)}}},$

where C₂ is the capacitance value of the second capacitor 760. The closed state of the fuse 756 thus corresponds to a first resonant state of the transponder 712. When the fuse 756 is opened, the resonant frequency is given by

$f_{r} = {\frac{1}{2\pi \sqrt{L_{1}C_{1}}}.}$

The open state of the fuse 756 thus corresponds to a second resonant state of the transponder 712. As described in the above embodiments, the fuse 756 may be mechanically, electrically or thermally actuated substantially simultaneously with a firing operation. The control unit 696 may be configured to determine the resonant state of the transponder 712 (and thus the unfired/fired state of the staple cartridge 538) by discriminating between the two resonant frequencies. Advantageously, because the resonant circuit 756 (and thus the microchip 754) continue to operate after the fuse 756 is opened, the control unit 696 may continue to receive data from the transponder 712. It will be appreciated that the placement of the fuse 756 and use of the second capacitor 760 to alter the resonant frequency is provided by way of example only. In other embodiments, for example, the fuse 756 may be connected such that the inductive value of the inductive element 750 is changed when the fuse 756 is opened (e.g., by connecting the fuse 756 such that a portion of the inductive element 750 is short-circuited when the fuse 756 is closed).

According to various embodiments, a switch may be used as an alternative to the fuse 756 for effecting the transition between transponder states. For example, as shown in FIG. 43, the staple cartridge tray 568 of the staple cartridge 538 may include a switch 762 (e.g., a normally-open limit switch) located at its proximal end. The switch 762 may be mounted such that when the sled 536 is present in the unfired position, the sled 536 maintains the switch 762 in a closed (e.g., conductive) state. When the sled 536 is driven from the unfired position to the fired position during a firing operation, the switch 762 transitions to an open (e.g., non-conductive state), thus effecting a transition in the state of the transponder 712 as described above. It will be appreciated that in other embodiments the switch 762 may be a normally-closed switch mounted at the distal end of the staple cartridge tray 568 such that the switch 762 is caused to open when the sled 536 is present in the fired position. It will further be appreciated that the switch 762 may be located at the proximal or distal ends of the staple cartridge 538 and mounted such that it may be suitably actuated by the sled 536 when present in the unfired and fired positions, respectively.

As an alternative to connecting the mechanically-actuated fuse 756 or the switch 762 to disable/alter the resonant circuit 749, these components may instead be connected to data inputs of the microchip 754. In this way, the open/closed states of the mechanically-actuated fuse 756 or the switch 762 may be transmitted to the control unit 696 in the same manner as the data corresponding to other end effector conditions.

As an alternative to the fuse 756 and the switch 762, embodiments of the present application may instead utilize alterable data values in a dynamic memory device 755 of the transponder 712. For example, the dynamic memory device 755 may store a first data value (e.g., a data bit having a value of 1) corresponding to a first data state of the transponder 712. The first data value may be written to the dynamic memory device 755 during the manufacture of the staple cartridge 538, for example. The first data state may thus be indicative of the unfired state of the staple cartridge 538. Based on a determination of the first data state of the transponder 712, the control unit 696 may enable operation of the instrument 510 if the end effector conditions are otherwise suitable for conducting a firing operation. Substantially simultaneously with the firing operation, the control unit 696 may transmit a wireless signal to the transponder 712 containing a second data value (e.g., a data bit having a value of 0). The second data value may be stored to the dynamic memory device 755 such that the first data value is overwritten, thus transitioning the transponder 712 from the first data state to a second data state. The second data state may thus be indicative of the fired state of the staple cartridge 538. If an attempt is made to reuse the staple cartridge 538, the control unit 696 may determine that the transponder 712 is in the second data state and prevent a firing operation from being enabled.

Although the transponders 712 in the above-described embodiments includes a microchip 754 for wirelessly communicating data stored in memory devices 735, 737 and data input from the sensors 735, in other embodiments the transponder may not include a microchip 754. For example, FIG. 44 illustrates a “chipless” transponder 764 in the form of a resonant circuit having components similar to those of the resonant circuit 749, such as an inductive element 750, a capacitor 752, and a fuse 756. Additionally, the transponder 764 may include one or more sensors 735 connected in series with the components 750, 752, 756. In certain embodiments and as shown, each sensor 735 may be a limit switch (e.g., a normally open or a normally closed limit switch) mounted in the end effector 516 for sensing a corresponding end effector condition (e.g., a position of the anvil 528, a position of the sled 536, etc.). In such embodiments, each limit switch 735 may be in a closed (e.g., conductive) state when its sensed condition is compatible with a firing operation, thus establishing electrical continuity through the resonant circuit.

When each switch 735 and the fuse 756 is in the closed state, the resonant circuit will be caused to resonate at a frequency f_(r) responsive to a magnetic field emitted by the distal inductive element 718. The closed states of the fuse 756 and the switches 735 thus correspond to an enabled state of the transponder 764 that is indicative of, among other things, the unfired state of the staple cartridge 538. The control unit 696 may sense the resonance (e.g., by sensing magnetic field loading caused by the resonant circuit) to determine the enabled state, at which time the control unit 596 may enable operation of the instrument 510. Substantially simultaneously with the actuation of the cutting instrument 534, the fuse 756 may be mechanically, electronically or thermally actuated as described above, thus transitioning the transponder 764 to a disabled state indicative of the fired state of the staple cartridge 538. If a subsequent firing operation is attempted without replacing the staple cartridge 538, the control unit 696 may determine the disabled state based on the absence of a sensed resonance in response to an emitted magnetic field, in which case the control unit 696 prevents the firing operation from being performed.

FIG. 45 illustrates another embodiment of a chipless transponder 764 in the form of a resonant circuit including an inductive element 750, a first capacitor 757, a second capacitor 760, and a fuse 756 connected in series with the second capacitor 760. The fuse 756 may be mechanically, electronically or thermally actuated substantially simultaneously with a firing operation, as in above-described embodiments. The transponder 764 may additionally include one or more sensors 735 (e.g., limit switches) connected in series with a third capacitor 766 of the resonant circuit. Accordingly, when each switch 735 and the fuse 756 are in the closed state, the resonant circuit will be caused to resonate at a frequency

$f_{r\; 1} = \frac{1}{2\pi \sqrt{L_{1}\left( {C_{1} + C_{2} + C_{3}} \right)}}$

responsive to a magnetic field emitted by the distal inductive element 718. When one of the switches 735 is opened and the fuse 756 is closed, the resonant frequency will be

${f_{r\; 2} = \frac{1}{2\pi \sqrt{L_{1}\left( {C_{1} + C_{2}} \right)}}},$

and when each of the switches 735 is closed and the fuse 756 is opened, the resonant frequency will be

$f_{r\; 3} = {\frac{1}{2\pi \sqrt{L_{1}\left( {C_{1} + C_{3}} \right)}}.}$

When the switches 735 and the fuse 756 are opened, the resonant frequency will be

$f_{r\; 4} = {\frac{1}{2\pi \sqrt{L_{1}C_{1}}}.}$

The closed states of the fuse 756 and the switches 735 correspond to a first resonant state (e.g., resonant frequency f_(r1)) of the transponder 764, and the open state of the fuse 756 corresponds to a second resonant state (e.g., either of resonant frequencies f_(r3) or f_(r4)). The capacitance values C₁, C₂ and C₃ may be selected such that the resonant frequencies f_(r1), f_(r2), f_(r3) and f_(r4) are different. The control unit 696 may be configured to discriminate between resonant frequencies to determine the first or second state of the transponder 766 (and thus the unfired or fired state of the staple cartridge 538), and to enable or prevent operation of the instrument 510 accordingly. The control unit 696 may further be configured to determine a third state of the transponder 764 corresponding the closed state of the fuse 756 and an open state of any of the switches 735. In this case, the control unit 696 may operate to prevent a firing operation until the end effector condition(s) causing the open switch(es) 735 is resolved.

FIG. 46 is a flow diagram of a method of preventing reuse of a staple cartridge in surgical instrument that may be performed in conjunction with embodiments of the instrument 510 described above. At step 800, a first wireless signal is transmitted to the transponder 712, 764 and at step 805 a second wireless signal is received from the transponder 712, 764 such that one of a first electronic state and a second electronic state of the transponder 712, 764 may be determined based on the second wireless signal. In certain embodiments and as explained above, the wireless signals may be magnetic signals generated by inductive effects, although electric fields and electromagnetic fields may alternatively be employed. States of the transponder 712, 764 are indicative of states of the staple cartridge 538. In certain embodiments, for example, the first and second transponder states may indicate the unfired and fired states of the staple cartridge 538, respectively.

At step 810, if the first electronic state (indicative of an unfired staple cartridge state) is determined, the cutting instrument 534 may be enabled at step 815. After the instrument 510 is enabled, the operator may initiate a firing operation when ready.

At step 820, the transponder 712, 764 may be transitioned from the first electronic state to the second electronic state substantially simultaneously with an actuation of the cutting instrument 534. Accordingly, if an attempt is made to reuse the staple cartridge 538 at step 800, the second electronic state of the transponder 712, 764 (indicative of the fired staple cartridge state) may be determined at step 810 and a firing operation consequently prevented, as shown at step 825.

Above-described embodiments advantageously prevent operation of the instrument 510 when a spent staple cartridge 538 (or no staple cartridge 538) is present in the end effector 516, thus preventing cutting of tissue without simultaneous stapling. In addition to preventing operation of the instrument 510 under such circumstances, it may further be desirable to prevent operation of the instrument 510 after it has been used to perform a predetermined number of firing operations. Limiting the number of firing operations may be necessary, for example, so that use of the instrument 510 does not cause operational lifetimes of its various components (e.g., the cutting instrument 534, the battery 604, etc.) to be exceeded.

According to various embodiments, a limit on the number of firing operations may be implemented by the control unit 696 using, for example, a counter (not shown) contained within the processor 698. The counter may be incremented once for each firing operation indicated by one or more sensor inputs received by the control unit 696 (e.g., inputs received from the end-of-stroke and beginning-of-stroke sensors 656, 658 and the run-motor sensor 628). Subsequent to each firing operation, the processor 698 may compare the counter contents to a predetermined number. The predetermined number may be stored in the memory 700 of the processor 698 during instrument manufacture, for example, and represent the maximum number of firing operations performable by the instrument 510. The predetermined number may be determined based upon, among other things, operational lifetimes of the various instrument components and/or the expected requirements of a medical procedure for which the instrument 510 is to be used. When the counted number of firing operations is equal to the predetermined number, the control unit 696 may be configured to prevent additional firing operations by the instrument 510. In embodiments in which the control unit 696 directly or indirectly controls rotation of the motor 606 (e.g., via a PWM signal output in response to an input from the run-motor sensor 628), instruction code stored in the memory 700 may cause the processor 698 to prevent further output of power and/or control signals necessary for motor operation.

In other embodiments, the control unit 696 may prevent firing operations in excess of the predetermined number by disabling electronic components necessary for motor operation. For example, as shown in FIG. 47, the control unit 696 may be connected to the motor 606 via conductive leads 768, one of which includes an electronically-actuated fuse 770. Subsequent to the retraction of the cutting instrument 534 after the final firing operation (e.g., when the number of firing operations is equal to the predetermined number), the control unit 696 may cause increased current to be applied to the motor 606 such that the fuse 770 is opened (e.g., rendered non-conductive), thus preventing further motor operation. It will be appreciated that the placement of the fuse 770 is shown by way of example only, and that the fuse 770 may be connected in other ways to effect the same result. For example, the fuse 770 may be connected between the battery 604 and the electrical components of the instrument 510. In such embodiments, when the number of firing operations equals the predetermined number, the control unit 696 may short circuit the fuse 770 such that it is caused to open, thus removing power from the electrical components.

As an alternative to the fuse 770, it will be appreciated that a switch (e.g., a relay contact) controllable by a discrete output of the control unit 696 may be used instead. Additionally, it will be appreciated the control unit 696 may be configured to electronically disable one or more components necessary for motor operation (e.g., capacitors, transistors, etc.) other than a fuse by applying excessive voltages and/or currents thereto. Such components may be internal or external to the control unit 696.

Although above-described embodiments for limiting instrument use utilize a counter within the processor 698, it will be appreciated that other embodiments may utilize an electro-mechanical counter having a mechanical input suitably coupled to a component of the instrument 510 (e.g., the firing trigger 524) such that the counter is incremented once for each firing operation. The counter may include a set of electrical contacts that close (or open) when the counted number of firing operations exceeds a predetermined number stored within the counter. The contacts may serve as an input to the control unit 696, and the processor 698 may be programmed to enable or disable instrument operation based on the state of the contacts. Alternatively, the contacts may be connected to other components of the instrument (e.g., the battery 604 or the motor 606) such that power to the motor 606 is interrupted when the predetermined number of counts is exceeded.

In the embodiments described above, the battery 604 powers (at least partially) the firing operation of the instrument 510. As such, the instrument may be a so-called “power-assist” device. More details and additional embodiments of power-assist devices are described are described in pending U.S. patent application Ser. No. 11/343,573 referenced above, which is incorporated herein. It should be recognized, however, that the instrument 510 need not be a power-assist device and that this is merely an example of a type of device that may utilize aspects of the present application. For example, the instrument 510 may include a user display (such as a LCD or LED display) that is powered by the battery 604 and controlled by the control unit 696. Data from the transponder 712, 764 in the end effector 516 may be displayed on such a display.

In another embodiment, the shaft 514 of the instrument 510, including for example, the proximate closure tube 572 and the distal closure tube 574, may collectively serve as part of an antenna for the control unit 696 by radiating signals to the transponder 712, 764 and receiving radiated signals from the transponder 712, 764. That way, signals to and from the transponder 712, 764 in the end effector 516 may be transmitted via the shaft 514 of the instrument 510.

The proximate closure tube 572 may be grounded at its proximate end by the exterior lower and upper side pieces 596, 598, which may be made of a nonelectrically conductive material, such as plastic. The drive shaft assembly components (including the main drive shaft 580 and secondary drive shaft 582) inside the proximate and distal closure tubes 572, 574 may also be made of a nonelectrically conductive material, such as plastic. Further, components of end effector 516 (such as the anvil 528 and the channel 526) may be electrically coupled to (or in direct or indirect electrical contact with) the distal closure tube 574 such that they may also serve as part of the antenna. Further, the transponder 712, 764 could be positioned such that it is electrically insulated from the components of the shaft 514 and end effector 516 serving as the antenna. For example, as discussed above, the transponder 712, 764 may be positioned in the staple cartridge 538, which may be made of a nonelectrically conductive material, such as plastic. Because the distal end of the shaft 514 (such as the distal end of the distal closure tube 574) and the portions of the end effector 516 serving as the antenna may be relatively close in distance to the transponder 712, 764, the power for the transmitted signals may be controlled such that interference with other systems in the use environment of the instrument 510 is reduced or minimized.

In such an embodiment, as shown in FIG. 48, the control unit 696 may be electrically coupled to the shaft 514 of the instrument 510, such as to the proximate closure tube 572, by a conductive link 772 (e.g., a wire). Portions of the outer shaft 514, such as the closure tubes 572, 574, may therefore act as part of an antenna for the control unit 696 by transmitting signals to the transponder 712, 764 and receiving signals transmitted by the transponder 712, 764. Signals received by the control unit 696 may be demodulated by the demodulator 704 and decoded by the decoder 706, as described above.

To transmit data signals to or from the transponder 712, 764 in the end effector 516, the link 772 may connect the control unit 696 to components of the shaft 514 of the instrument 510, such as the proximate closure tube 572, which may be electrically connected to the distal closure tube 574. The distal closure tube 574 is preferably electrically insulated from the transponder 712, 764, which may be positioned in the plastic staple cartridge 538. As mentioned before, components of the end effector 516, such as the channel 526 and the anvil 528, may be conductive and in electrical contact with the distal closure tube 574 such that they, too, may serve as part of the antenna.

With the shaft 514 acting as the antenna for the control unit 696, the control unit 696 can communicate with the transponder 712, 764 in the end effector 516 without a hardwired connection. In addition, because the distance between shaft 514 and the transponder 712, 764 is fixed and known, the power levels could be optimized to thereby minimize interference with other systems in the use environment of the instrument 510.

In another embodiment, the components of the shaft 514 and/or the end effector 516 may serve as an antenna for the transponder 712, 764. In such an embodiment, the transponder 712, 764 is electrically connected to the shaft 514 (such as to distal closure tube 574, which may be electrically connected to the proximate closure tube 572) and the control unit 696 is insulated from the shaft 514. For example, the transponder 712, 764 could be connected to a conductive component of the end effector 516 (such as the channel 526), which in turn may be connected to conductive components of the shaft (e.g., the closure tubes 572, 574). Alternatively, the end effector 516 may include a wire (not shown) that connects the transponder 712, 764 the distal closure tube 574.

The various embodiments of embodiments of the present application have been described above in connection with cutting-type surgical instruments. It should be noted, however, that in other embodiments, the inventive surgical instrument disclosed herein need not be a cutting-type surgical instrument, but rather could be used in any type of surgical instrument including remote sensor transponders. For example, it could be a non-cutting endoscopic instrument, a grasper, a stapler, a clip applier, an access device, a drug/gene therapy delivery device, an energy device using ultrasound, RF, laser, etc. In addition, embodiments of the present application may be in laparoscopic instruments, for example. Embodiments of the present application also have application in conventional endoscopic and open surgical instrumentation as well as robotic-assisted surgery.

The devices disclosed herein can be designed to be disposed of after a single use, or they can be designed to be used multiple times. In either case, however, the device can be reconditioned for reuse after at least one use. Reconditioning can include any combination of the steps of disassembly of the device, followed by cleaning or replacement of particular pieces, and subsequent reassembly. In particular, the device can be disassembled, and any number of the particular pieces or parts of the device can be selectively replaced or removed in any combination. Upon cleaning and/or replacement of particular parts, the device can be reassembled for subsequent use either at a reconditioning facility, or by a surgical team immediately prior to a surgical procedure. Those skilled in the art will appreciate that reconditioning of a device can utilize a variety of techniques for disassembly, cleaning/replacement, and reassembly. Use of such techniques, and the resulting reconditioned device, are all within the scope of the present application.

Although embodiments of the present application have been described herein in connection with certain disclosed embodiments, many modifications and variations to those embodiments may be implemented. For example, different types of end effectors may be employed. Also, where materials are disclosed for certain components, other materials may be used. The foregoing description and following claims are intended to cover all such modification and variations.

Any patent, publication, or other disclosure material, in whole or in part, that is said to be incorporated by reference herein is incorporated herein only to the extent that the incorporated materials does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material. 

1. A method of preventing reuse of a staple cartridge in a surgical instrument, the method comprising: transmitting a first wireless signal to a transponder disposed within the staple cartridge; receiving a second wireless signal from the transponder to determine one of a first electronic state and a second electronic state of the transponder based on the second wireless signal; enabling actuation of a cutting instrument of the surgical instrument when the first electronic state is determined; and transitioning the transponder from the first electronic state to the second electronic state substantially simultaneously with an actuation of the cutting instrument.
 2. The method of claim 1, comprising preventing actuation of the cutting instrument when the second electronic state is determined.
 3. The method of claim 1, comprising transmitting a third wireless signal to the transponder to electronically alter at least one component of the transponder.
 4. The method of claim 1, comprising electronically altering at least one component of the transponder responsive to a movement of the cutting instrument when actuated.
 5. A surgical instrument, comprising: an end effector comprising a moveable cutting instrument to cut an object; a motor coupled to the end effector to actuate the cutting instrument, each actuation of the cutting instrument corresponding to a firing operation by the surgical instrument; and a control unit to count a number of firing operations by the surgical instrument and to electronically alter at least one component of the surgical instrument when the number of firing operations is equal to a predetermined number, wherein the altered at least one component prevents firing operations by the surgical instrument in excess of the predetermined number.
 6. The surgical instrument of claim 5, wherein each of the at least one component is selected from the group consisting of an electronically-actuated fuse and a switch.
 7. A method of configuring a surgical instrument to prevent reuse of a staple cartridge in the surgical instrument, the surgical instrument comprising a control unit to wirelessly communicate with a transponder contained in the staple cartridge, the control unit comprising a processor and a memory, the method comprising: programming the processor to cause the control unit to: transmit a first wireless signal to the transponder and determine an electronic state of the transponder based on receipt or non-receipt of a second wireless signal from the transponder by the control unit in response to the transmission of the first wireless signal, wherein a first electronic state of the transponder corresponds to an unfired state of the staple cartridge, and wherein a second electronic state of the transponder corresponds to a fired state of the staple cartridge; and enable actuation of a cutting instrument of the surgical instrument when the first electronic state is determined and prevent actuation of the cutting instrument when the second electronic state is determined.
 8. The method of claim 7, comprising programming the processor to cause the control unit to: transmit a third wireless signal to the transponder when the cutting instrument is actuated to effect a transition of the transponder from the first electronic state to the second electronic state.
 9. The method of claim 7, comprising programming the processor to determine the first electronic state or the second electronic state based on receipt of the second wireless signal by the control unit.
 10. The method of claim 7, comprising programming the processor to determine the first electronic state based on receipt of the second wireless signal by the control unit and determine the second electronic state based on nonreceipt of the second wireless signal by the control unit. 